Contents

Yamaha YFM25RX Raptor 250 2008 Owner's Manual PDF

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Summary of Content for Yamaha YFM25RX Raptor 250 2008 Owner's Manual PDF

This A

OWNERS MANUAL

LIT-11626-21-22 4D3-28199-10

i TV should not be ridden by anyone under 16 years of age.

YFM25RX WARNING

READ THIS MANUAL CAREFULLY! It contains important safety information.

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INTRODUCTION

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Congratulations on your purchase of the Yamaha YFM25RX. This ATV represents the result of many years of Yamaha experience in the production of fine sporting, touring, and pacesetting racing machines. With the purchase of this Yamaha, you can now appreciate the high degree of craftsmanship and reliability that have made Yamaha a leader in these fields. This manual will provide you with a good basic understanding of the features and operation of this ATV.

This manual includes important safety information. It provides information about special tech- niques and skills necessary to ride the ATV.

It also includes basic maintenance and inspection proce- dures. If you have any questions regarding the operation or maintenance of your ATV, please consult a Yamaha dealer.

AN IMPORTANT SAFETY MESSAGE:

READ THIS MANUAL TOGETHER WITH TIPS FOR THE ATV RIDER CAREFULLY AND COMPLETE- LY BEFORE OPERATING YOUR ATV. MAKE SURE YOU UNDERSTAND ALL INSTRUCTIONS.

PAY CLOSE ATTENTION TO THE WARNING AND CAUTION LABELS ON THE ATV.

NEVER OPERATE AN ATV WITHOUT PROPER TRAINING OR INSTRUCTION. FREE TRAINING IS AVAILABLE TO ANYONE WHO BUYS A NEW ATV. CALL 1-800-887-2887 FOR MORE INFORMA- TION.

THIS ATV, AND ANY OTHER ATV OVER 90 cc, SHOULD NOT BE RIDDEN BY ANYONE UNDER 16 YEARS OF AGE.

THIS ATV IS A HIGH-PERFORMANCE ATV FOR OFF-ROAD USE ONLY, FOR SPORT-TYPE REC- REATIONAL AND COMPETITIVE USE BY EXPERIENCED OPERATORS.

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IMPORTANT MANUAL INFORMATION

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FAILURE TO FOLLOW THE WARNINGS CONTAINED IN THIS MANUAL CAN RESULT IN SERIOUS IN- JURY OR DEATH. Particularly important information is distinguished in this manual by the following notations:

* Product and specifications are subject to change without notice.

The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED!

Failure to follow WARNING instructions could result in severe injury or death to the ATV operator, a bystander, or a person inspecting or repairing the ATV.

A CAUTION indicates special precautions that must be taken to avoid damage to the ATV.

A NOTE provides key information to make procedures easier or clearer.

WARNING

CAUTION:

NOTE:

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IMPORTANT NOTICE

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Welcome to the Yamaha world of motor sports! This ATV is designed and manufactured for OFF-ROAD use only. It is illegal and unsafe to operate this ATV on any public street, road or highway. This ATV complies with all applicable OFF-ROAD noise level and spark arrester laws and regulations in effect at the time of manufacture. Please check your local riding laws and regulations before operating this ATV.

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AFFIX DEALER

LABEL HERE

YFM25RX OWNERS MANUAL

2007 by Yamaha Motor Corporation, U.S.A. 1st edition, May 2007 All rights reserved.

Any reprinting or unauthorized use without the written permission of Yamaha Motor Corporation, U.S.A.

is expressly prohibited. Printed in Japan.

P/N LIT-11626-21-22

WARNING

EWB00010

Indicates a potential hazard that could result in serious injury or death.

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TABLE OF CONTENTS

SAFETY INFORMATION .............................. 1-1

LOCATION OF THE WARNING AND SPECIFICATION LABELS ............................ 2-1

DESCRIPTION .............................................. 3-1 Left view ..................................................... 3-1 Right view................................................... 3-1 Controls and instruments ........................... 3-2

INSTRUMENT AND CONTROL FUNCTIONS .................................................. 4-1

Main switch ............................................... 4-1 Indicator light ............................................. 4-2 Handlebar switches ................................... 4-2 Throttle lever ............................................. 4-3 Speed limiter ............................................. 4-4

Clutch lever ................................................ 4-5 Brake lever ................................................. 4-5 Brake pedal ................................................ 4-6 Parking brake lever .................................... 4-6 Shift pedal .................................................. 4-7 Fuel tank cap ............................................. 4-8 Fuel ............................................................ 4-8 Fuel cock ................................................. 4-10 Starter (choke) ......................................... 4-11 Seat ......................................................... 4-12 Adjusting the front shock absorber

assemblies ............................................. 4-13

PRE-OPERATION CHECKS ..........................5-1 Pre-operation check list ............................. 5-1 Fuel ............................................................ 5-4 Engine oil ................................................... 5-4 Front and rear brakes ................................ 5-4 Throttle lever .............................................. 5-5 Drive chain ................................................. 5-5 Tires ........................................................... 5-7 Measuring the tire pressure ....................... 5-8 Tire wear limit ............................................ 5-9 Chassis fasteners ...................................... 5-9 Instruments, lights and switches ................ 5-9

OPERATION...................................................6-1 Starting a cold engine ................................ 6-1 Starting a warm engine .............................. 6-3

Shifting ...................................................... 6-3 Engine break-in ......................................... 6-5 Parking ...................................................... 6-6 Parking on a slope .................................... 6-6 Accessories and loading ........................... 6-7

RIDING YOUR ATV ...................................... 7-1 GETTING TO KNOW YOUR ATV.............. 7-2 RIDE WITH CARE AND GOOD

JUDGEMENT........................................... 7-2 BE CAREFUL WHERE YOU RIDE.......... 7-12 TURNING YOUR ATV ............................. 7-17 CLIMBING UPHILL .................................. 7-19 RIDING DOWNHILL................................. 7-22 CROSSING A SLOPE.............................. 7-24 CROSSING THROUGH SHALLOW

WATER .................................................. 7-25 RIDING OVER ROUGH TERRAIN .......... 7-27 SLIDING AND SKIDDING........................ 7-28 WHAT TO DO IF... ................................... 7-29 WHAT TO DO... ....................................... 7-29

PERIODIC MAINTENANCE AND MINOR REPAIR.......................................................... 8-1

Owners manual and tool kit ...................... 8-1 Periodic maintenance chart for the

emission control system .......................... 8-3 General maintenance and lubrication

chart ........................................................ 8-5

Checking the spark plug ............................ 8-9 Engine oil and oil filter element ................ 8-11 Cleaning the air filter element .................. 8-15 Cleaning the spark arrester ..................... 8-19 Adjusting the carburetor ........................... 8-20 Adjusting the engine idling speed ............ 8-21 Adjusting the throttle cable free play ........ 8-22 Valve clearance ....................................... 8-22 Checking the front and rear brake

pads ....................................................... 8-23 Checking the brake fluid level .................. 8-24 Changing the brake fluid .......................... 8-26 Checking the front brake lever free

play ........................................................ 8-27 Checking the brake pedal position ........... 8-27 Adjusting the parking brake free play ...... 8-28 Brake light switches ................................. 8-30 Adjusting the clutch lever free play .......... 8-31 Drive chain slack ...................................... 8-32 Lubricating the drive chain ....................... 8-33 Checking and lubricating the cables ........ 8-34 Checking and lubricating the brake and

clutch levers ........................................... 8-35 Checking and lubricating the brake and

shift pedals ............................................. 8-36 Checking the wheel hub bearings ............ 8-36 Lubricating the swingarm pivots .............. 8-36 Lubricating the upper and lower arm

pivots ..................................................... 8-37

Lubricating the steering shaft .................. 8-38 Battery ..................................................... 8-38 Replacing the fuse .................................. 8-40 Replacing a headlight bulb ...................... 8-42 Adjusting a headlight beam ..................... 8-44 Replacing the tail/brake light bulb ........... 8-44 Removing a wheel ................................... 8-44 Installing a wheel ..................................... 8-45 Troubleshooting ...................................... 8-45 Troubleshooting chart ............................. 8-47

CLEANING AND STORAGE.......................... 9-1 Cleaning .................................................... 9-1 Storage ...................................................... 9-2

SPECIFICATIONS ...................................... 10-1

CONSUMER INFORMATION ...................... 11-1 Identification numbers ............................. 11-1 Noise regulation ...................................... 11-3 Maintenance record ................................ 11-4 YAMAHA MOTOR CORPORATION,

U.S.A. ATV LIMITED WARRANTY ....... 11-5 YAMAHA EXTENDED SERVICE

(Y.E.S.) .................................................. 11-7

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SAFETY INFORMATION

SAFETY INFORMATION

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AN ATV IS NOT A TOY AND CAN BE HAZARD- OUS TO OPERATE.

An ATV handles differently from other vehicles, in- cluding motorcycles and cars. A collision or roll- over can occur quickly, even during routine maneuvers such as turning and riding on hills or over obstacles, if you fail to take proper precau- tions. SEVERE INJURY OR DEATH can result if you do not follow these instructions:

Read this manual and all labels carefully and fol- low the operating procedures described.

Never operate an ATV without proper training or instruction.

Take a Training Course.

Beginners should receive training from a certified instruc- tor. Contact an authorized ATV dealer or call 1- 800-887-2887 to find out about the training courses nearest you.

Always follow the age recommendation: A child under 16 years old should never oper-

ate an ATV with engine size greater than 90 cc.

Never allow a child under age 16 to operate an ATV without adult supervision, and never allow continued use of an ATV by a child if he or she does not have the abilities to operate it safely.

Never carry a passenger on an ATV.

Always avoid operating an ATV on any paved surfaces, including sidewalks, driveways, park- ing lots and streets.

Never operate an ATV on any public street, road or highway, even a dirt or gravel one.

Never operate an ATV without wearing an ap- proved motorcycle helmet that fits properly. You should also wear eye protection (goggles or face shield), gloves, boots, a long-sleeved shirt or a jacket, and long pants.

Never consume alcohol or drugs before or while operating this ATV.

Never operate at speeds too fast for your skills or the riding conditions. Always go at a speed that is proper for the terrain, visibility, operating conditions, and your experience.

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Never attempt wheelies, jumps, or other stunts.

Always inspect your ATV each time you use it to make sure it is in safe operating condition. Al- ways follow the inspection and maintenance procedures and schedules described in this manual.

Always keep both hands on the handlebars and both feet on the footpegs of the ATV during op- eration.

Always go slowly and be extra careful when op- erating on unfamiliar terrain. Always be alert to changing terrain conditions when operating the ATV.

Never operate on excessively rough, slippery or loose terrain until you have learned and prac- ticed the skills necessary to control the ATV on such terrain. Always be especially cautious on these kinds of terrain.

Always follow proper procedures for turning as described in this manual. Practice turning at low speeds before attempting to turn at faster speeds and never turn at excessive speeds.

Never operate the ATV on hills too steep for the ATV or for your abilities. Practice on smaller hills before attempting larger hills.

Always follow proper procedures for climbing

hills as described in this manual. Check the ter- rain carefully before you start up any hill. Never climb hills with excessively slippery or loose sur- faces. Shift your weight forward. Never open the throttle suddenly or make sudden gear changes. Never go over the top of a hill at high speed.

Always follow proper procedures for going down hills and for braking on hills as described in this manual. Check the terrain carefully before you start down any hill. Shift your weight backward. Never go down a hill at high speed. Avoid going down a hill at an angle that would cause the ve- hicle to lean sharply to one side. Go straight down the hill where possible.

Always follow proper procedures for crossing the side of a hill as described in this manual. Avoid hills with excessively slippery or loose sur- faces. Shift your weight to the uphill side of the ATV. Never attempt to turn the ATV around on any hill until you have mastered the turning tech- nique described in this manual on level ground. Avoid crossing the side of a steep hill if possible.

Always use proper procedures if you stall or roll backwards when climbing a hill. To avoid stall- ing, use the proper gear and maintain a steady speed when climbing a hill. If you stall or roll

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backwards, follow the special procedure for braking described in this manual. Dismount on the uphill side or to a side if pointed straight up- hill. Turn the ATV around and remount, following the procedure described in this manual.

Always check for obstacles before operating in a new area.

Never attempt to operate over large obstacles, such as large rocks or fallen trees. Always follow proper procedures when operating over obsta- cles as described in this manual.

Always be careful when skidding or sliding. Learn to safely control skidding or sliding by practicing at low speeds and on level, smooth terrain. On extremely slippery surfaces, such as ice, go slowly and be very cautious in order to re- duce the chance of skidding or sliding out of con- trol.

Never operate an ATV in fast flowing water or in water deeper than that recommended in this manual. Remember that wet brakes may have reduced stopping ability. Test your brakes after leaving water. If necessary, apply them several times to let friction dry out the linings.

Always use the size and type of tires specified in this manual.

Always maintain proper tire pressure as de- scribed in this manual.

Never modify an ATV through improper installa- tion or use of accessories.

Never exceed the stated load capacity for an ATV. Cargo should be properly distributed and securely attached. Reduce speed and follow in- structions in this manual for carrying cargo or pulling a trailer. Allow greater distance for brak- ing.

FOR MORE INFORMATION ABOUT ATV SAFE- TY,

call the Consumer Products Safety Commis- sion at 1-800-638-2772, or the ATV Distributors Safety Hotline at 1-800-852-5344.

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EWB00021

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WARNING

POTENTIAL HAZARD Improper handling of gasoline. WHAT CAN HAPPEN Gasoline can catch fire and you could be burned. HOW TO AVOID THE HAZARD Always turn off the engine when refueling. Do not refuel right after the engine has been running and is still very hot. Do not spill gasoline on the engine or ex- haust pipe/muffler when refueling. Never refuel while smoking, or in the vicinity of sparks, open flames, or other sources of ignition such as the pilot lights of water heat- ers and clothes dryers. When transporting the ATV in another vehi- cle, be sure it is kept upright and that the fuel cock is in the OFF position. Otherwise, fuel may leak out of the carburetor or fuel tank. WHAT CAN HAPPEN Gasoline is poisonous and can cause inju- ries.

HOW TO AVOID THE HAZARD If you should swallow some gasoline or in- hale a lot of gasoline vapor, or get some gas- oline in your eyes, seek medical help immediately. If gasoline spills on your skin, wash with soap and water. If gasoline spills on your clothing, change your clothes.

WARNING

POTENTIAL HAZARD Starting or running the engine in a closed ar- ea.

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WHAT CAN HAPPEN Exhaust fumes are poisonous and may cause loss of consciousness and death with- in a short time. HOW TO AVOID THE HAZARD Always operate your ATV in an area with ad- equate ventilation.

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LOCATION OF THE WARNING AND SPECIFICATION LABELS

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Read and understand all of the labels on your ATV. These labels contain important information for safe and proper operation. Never remove any labels from your ATV. If a label becomes difficult to read or comes off, request a replace- ment label from your Yamaha dealer.

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NEVER

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DESCRIPTION

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Left view

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Right view

1. Headlights 2. Fuel cock 3. Starter (choke) 4. Throttle stop screw 5. Fuse 6. Tail/brake light 7. Shift pedal

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1. Spark arrester 2. Seat 3. Fuel tank cap 4. Oil lter element 5. Brake pedal

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Controls and instruments

NOTE:

The ATV you have purchased may differ slightly

from the figures shown in this manual.

1. Clutch lever 2. Handlebar switches 3. Parking brake lever 4. Main switch 5. Throttle lever 6. Brake lever

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INSTRUMENT AND CONTROL FUNCTIONS

WARNING

EWB00010

Indicates a potential hazard that could result in serious injury or death.

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Main switch

The positions of the main switch are as follows:

ON

All electrical systems are supplied with power, and the engine can be started. The key cannot be re- moved.

OFF

All electrical systems are off. The key can be re- moved.

1. Main switch

OFF ON

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Indicator light

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Neutral indicator light

This indicator light comes on when the transmis- sion is in the neutral position.

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Handlebar switches

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Engine stop switch ENG. STOP

Set this switch to RUN before starting the engine. The engine stop switch controls the ignition and stops the engine when it is running. Use this switch to stop the engine in an emergency situation. The engine will not start or run when this switch is set to OFF.

1. Neutral indicator light N

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1. Light switch LIGHTS 2. Engine stop switch ENG. STOP 3. Start switch START

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Start switch START

Push this switch to crank the engine with the start- er.

CAUTION:

ECB00050

See the starting instructions on page 6-1 prior

to starting the engine.

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Light switch LIGHTS

Set this switch to LO to turn on the low beams and the taillight. Set the switch to HI to turn on the high beams and the taillight. Set the switch to OFF to turn off all the lights.

NOTE:

The headlights and the taillight can be turned on

only when the engine is running.

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Throttle lever

Once the engine is running, movement of the throt- tle lever will increase the engine speed. Regulate the speed of the ATV by varying the throttle position. Because the throttle is spring- loaded, the ATV will decelerate, and the engine will

return to an idle any time the hand is removed from the throttle lever.

Before starting the engine, check the throttle to be sure it is operating smoothly. Make sure it returns to the idle position as soon as the lever is released.

EWB00200

1. Throttle lever

WARNING

POTENTIAL HAZARD Malfunction of throttle. WHAT CAN HAPPEN The throttle could be hard to operate, making it difficult to speed up or slow down when you need to. This could cause an accident.

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Speed limiter

Your ATV was delivered with an adjustable speed limiter. The speed limiter keeps the throttle from fully opening, even when the throttle lever is pushed to the maximum. 1. Loosen the locknut. 2. To increase the maximum engine power avail-

able and the maximum speed of the ATV, turn the adjusting screw in direction (a). To de- crease the maximum engine power available and the maximum speed of the ATV, turn the adjusting screw in direction (b).

3. Tighten the locknut.

HOW TO AVOID THE HAZARD Check the operation of the throttle lever be- fore you start the engine. If it does not work smoothly, check for the cause. Correct the problem before riding the ATV. Consult a Yamaha dealer if you cant find or solve the problem yourself.

1. Locknut 2. Adjusting screw 3. No more than 12 mm (0.47 in)

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(b)

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Clutch lever

The clutch lever is located on the left handlebar and the ignition circuit cut-off system is incorporat- ed in the clutch lever holder. To disengage the clutch, pull the clutch lever toward the handlebar grip. To engage the clutch, release the clutch lever. The clutch lever should be pulled rapidly and re- leased slowly for smooth clutch operation. (See page 6-1 for a description of the ignition circuit cut-

off system.)

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Brake lever

The brake lever is located at the right handlebar grip. To apply the front brake, pull the brake lever toward the handlebar grip.

WARNING

POTENTIAL HAZARD Improper adjustment of the speed limiter and throttle. WHAT CAN HAPPEN The throttle cable could be damaged. Im- proper throttle operation could result. You could lose control, have an accident or be in- jured. HOW TO AVOID THE HAZARD Do not turn the adjusting screw out more than 12 mm (0.47 in). Always make sure the throttle lever free play is adjusted to 2.04.0 mm (0.080.16 in). (See page 8-22.)

1. Clutch lever

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Brake pedal

The brake pedal is located on the right side of the ATV. To apply the rear brake, push down on the brake pedal.

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Parking brake lever

Use the parking brake before starting the engine or parking the ATV, especially on a slope. To apply the parking brake, move the parking brake lever in direction (a). To release the parking brake, move the parking brake lever in direction (b).

1. Brake lever

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Shift pedal

This ATV is equipped with a constant-mesh 5- speed transmission. The shift pedal is located on the left side of the engine and is used in combina- tion with the clutch when shifting.

1. Parking brake lever (locked position)

1. Parking brake lever (unlocked position)

WARNING

POTENTIAL HAZARD Improper use of the parking brake. WHAT CAN HAPPEN The ATV could start moving unexpectedly if the parking brake is not applied before start- ing the engine. This could cause loss of con- trol or a collision. The brake could overheat if you ride the ATV without releasing the parking brake. You could lose braking performance which could cause an accident. You could also wear out the brakes prematurely. HOW TO AVOID THE HAZARD Always set the parking brake before starting the engine. Always be sure you have released the park- ing brake before you begin to ride.

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Fuel tank cap

Remove the fuel tank cap by turning it counter- clockwise.

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Fuel

Make sure that there is sufficient fuel in the tank. Fill the fuel tank to the bottom of the filler tube as shown.

1. Shift pedal

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1. Fuel tank cap

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CAUTION:

ECB00070

Use only unleaded gasoline. The use of leaded gasoline will cause severe damage to internal engine parts, such as the valves and piston

rings, as well as to the exhaust system.

Your Yamaha engine has been designed to use regular unleaded gasoline with a pump octane number [(R+M)/2] of 86 or higher, or a research oc- tane number of 91 or higher. If knocking or pinging occurs, use a different brand of gasoline or premi- um unleaded fuel. Unleaded fuel will give you long- er spark plug life and reduced maintenance cost.

Gasohol

There are two types of gasohol: gasohol contain- ing ethanol and that containing methanol. Gasohol containing ethanol can be used if the ethanol con- tent does not exceed 10%. Gasohol containing methanol is not recommended by Yamaha be- cause it can cause damage to the fuel system or ATV performance problems.

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1. Fuel level 2. Filler tube

Recommended fuel: UNLEADED GASOLINE ONLY

Fuel tank capacity: 9.0 L (2.38 US gal) (1.98 Imp.gal)

Fuel reserve amount: 1.0 L (0.26 US gal) (0.22 Imp.gal)

WARNING

POTENTIAL HAZARD Improper care when refueling.

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Fuel cock

The fuel cock supplies fuel from the tank to the car- buretor while also filtering it. The fuel cock lever positions are explained as fol- lows and shown in the illustrations.

OFF

With the fuel cock lever in this position, fuel will not flow. Always turn the fuel cock lever to this position when the engine is not running.

WHAT CAN HAPPEN Fuel can spill, which can cause a fire and se- vere injury. Fuel expands when it heats up. If the fuel tank is overfilled, fuel could spill out due to heat from the engine or the sun. HOW TO AVOID THE HAZARD Do not overfill the fuel tank. Be careful not to spill fuel, especially on the engine or exhaust pipe. Wipe up any spilled fuel immediately. Be sure the fuel tank cap is closed securely. Do not refuel right after the engine has been running and is still very hot.

1. Arrow mark positioned over OFF

OFF

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ON

With the fuel cock lever in this position, fuel flows to the carburetor. Turn the fuel cock lever to this position when starting the engine and riding.

RES

This indicates reserve. With the fuel cock lever in this position, the fuel reserve is made available. Turn the fuel cock lever to this position if you run out of fuel while riding. When this occurs, refuel as soon as possible and be sure to turn the fuel cock lever back to ON!

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Starter (choke)

Starting a cold engine requires a richer air-fuel mix- ture, which is supplied by the starter (choke). Move the starter (choke) in direction (a) to turn on

1. Arrow mark positioned over ON

ON

1. Arrow mark positioned over RES

RES

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the starter (choke). Move the starter (choke) in direction (b) to turn off the starter (choke). See the Starting a cold engine section on page 6-1 for proper operation.

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Seat

To remove the seat

Insert your hand between the rear of the seat and the rear fender, pull the seat lock lever upward and pull up the seat at the rear.

To install the seat

Insert the projections on the front of the seat into the seat holders and push down on the seat at the rear.

NOTE:

Make sure that the seat is securely fitted.

1. Starter (choke)

(a) (b)

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Adjusting the front shock absorber assemblies

The spring preload can be adjusted to suit the rid- ers weight and the riding conditions. Adjust the spring preload as follows. Turn the adjusting ring in direction (a) to increase the spring preload and thereby harden the suspen- sion, and in direction (b) to decrease the spring preload and thereby soften the suspension.

NOTE:

A special wrench can be obtained at a Yamaha

dealer to make this adjustment.

1. Projection 2. Seat holder

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1. Spring preload adjusting ring 2. Special wrench 3. Position indicator

Spring preload setting: Minimum (soft):

A Standard:

B Maximum (hard):

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(b)

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EWB00350

WARNING

EWB00010

Indicates a potential hazard that could result in serious injury or death.

WARNING

POTENTIAL HAZARD Improper shock absorber assembly adjust- ment. WHAT CAN HAPPEN Uneven adjustment can cause poor handling and loss of stability, which could lead to an accident. HOW TO AVOID THE HAZARD Always adjust the shock absorber assem- blies on the left and right side to the same setting.

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PRE-OPERATION CHECKS

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Pre-operation check list

Before operating this ATV, be sure to check the items listed in the following table.

EWB00470

NOTE:

The maintenance of some items in the table has to be performed by a Yamaha dealer. Refer to the periodic

maintenance charts on page 8-3 to determine which service should be performed by a Yamaha dealer.

WARNING

POTENTIAL HAZARD Failure to inspect the ATV before operating. Failure to properly maintain the ATV. WHAT CAN HAPPEN Increases the possibility of an accident or equipment damage. HOW TO AVOID THE HAZARD Always inspect your ATV each time you use it to make sure it is in safe operating condition. Always follow the inspection and maintenance procedures and schedules described in the Own- ers Manual.

ITEM ROUTINE PAGE

Fuel

Check fuel level in fuel tank, and add recommended fuel if neces- sary.

Check fuel line for leakage. Correct if necessary. 4-8, 5-4

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Engine oil

Check oil level in engine, and add recommended oil to specied level if necessary.

Check ATV for oil leakage. Correct if necessary. 5-4, 8-11

Front brake

Check operation. If soft or spongy, have Yamaha dealer bleed hydraulic system.

Check brake pads for wear, and replace if necessary.

Check brake uid level in reservoir, and add recommended brake uid to specied level if necessary.

Check hydraulic system for leakage. Correct if necessary.

5-4, 8-23, 8-24, 8-27

Rear brake

Check operation. If soft or spongy, have Yamaha dealer bleed hydraulic system.

Check brake pads for wear, and replace if necessary.

Check brake uid level in reservoir, and add recommended brake uid to specied level if necessary.

Check hydraulic system for leakage. Correct if necessary.

5-4, 8-23, 8-24, 8-27

Clutch

Check operation, and correct if necessary.

Lubricate cable if necessary.

Check lever free play, and adjust if necessary. 8-31

Throttle lever

Make sure that operation is smooth. Lubricate cable and lever hous- ing if necessary.

Check cable free play, and adjust if necessary. 5-5, 8-22

Control cables

Make sure that operation is smooth. Lubricate if necessary. 8-34

Drive chain

Check chain slack, and adjust if necessary.

Check chain condition. Lubricate if necessary. 5-5, 8-32, 8-33

Wheels and tires

Check wheel condition, and replace if damaged.

Check tire condition and tread depth. Replace if necessary.

Check air pressure. Correct if necessary. 5-7, 5-8, 5-9

Brake and shift pedals

Make sure that operation is smooth. Lubricate pedal pivoting points if necessary. 8-36

Brake and clutch levers

Make sure that operation is smooth. Lubricate lever pivoting points if necessary. 8-35

ITEM ROUTINE PAGE

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Chassis fasteners

Make sure that all nuts, bolts and screws are properly tightened. 5-9

Instruments, lights and switches

Check operation, and correct if necessary. 5-9

ITEM ROUTINE PAGE

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EBU19530

Fuel

Make sure that there is sufficient fuel in the tank. (See page 4-8.)

EWB00500

EBU19560

Engine oil

Make sure that the engine oil is at the specified lev- el. Add oil as necessary. (See page 8-11.)

EBU19700

Front and rear brakes

Brake lever and brake pedal

Check that there is no free play in the brake le- ver. If there is free play, have a Yamaha dealer check the brake system.

Check for correct brake pedal height. (See page 8-27.) If the pedal height is incorrect, have a Yamaha dealer adjust it.

Check the operation of the lever and pedal. They should move smoothly and there should be a firm feeling when the brakes are applied. If not, have a Yamaha dealer check the brake system.

Brake fluid level

Check the brake fluid level. Add fluid if necessary. (See page 8-24.)

Brake fluid leakage

Check to see if any brake fluid is leaking out of the pipe joints or brake fluid reservoirs. Apply the brakes firmly for one minute. If there is any leak- age, have a Yamaha dealer check the brake sys-

WARNING

POTENTIAL HAZARD Improper care when refueling. WHAT CAN HAPPEN Fuel can spill, which can cause a fire and se- vere injury. Fuel expands when it heats up. If the fuel tank is overfilled, fuel could spill out due to heat from the engine or the sun. HOW TO AVOID THE HAZARD Do not overfill the fuel tank. Be careful not to spill fuel, especially on the engine or exhaust pipe. Wipe up any spilled fuel immediately. Be sure the fuel tank cap is closed securely. Do not refuel right after the engine has been running and is still very hot.

Recommended brake fluid: DOT 4

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tem.

Brake operation

Test the brakes at slow speed after starting out to make sure they are working properly. If the brakes do not provide proper braking performance, check the brake pads for wear. (See page 8-23.)

EWB00540

EBU19761

Throttle lever

Check the operation of the throttle lever. It must open smoothly and spring back to the idle position when released. Have a Yamaha dealer correct if

necessary.

EBU19770

Drive chain

Check the condition of the drive chain and check the drive chain slack. Lubricate and adjust the drive chain as necessary. (See page 8-32.)

WARNING

POTENTIAL HAZARD Riding with improperly operating brakes. WHAT CAN HAPPEN You could lose braking ability, which could lead to an accident. HOW TO AVOID THE HAZARD Always check the brakes at the start of every ride. Do not ride the ATV if you find any prob- lem with the brakes. If a problem cannot be corrected by the adjustment procedures pro- vided in this manual, have a Yamaha dealer check for the cause.

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EBU19781

Tires

EWB00561

WARNING

POTENTIAL HAZARD Operating this ATV with improper tires, or with improper or uneven tire pressure. WHAT CAN HAPPEN Use of improper tires on this ATV, or opera- tion of this ATV with improper or uneven tire pressure, may cause loss of control, increas- ing your risk of accident. HOW TO AVOID THE HAZARD

The tires listed below have been approved by Yamaha Motor Co., Ltd. for this model. Other tire combinations are not recom- mended. Front:

Manufacturer/model: DUNLOP/KT201

Size: AT20 x 7-10

Type: Tubeless

Rear: Manufacturer/model:

DUNLOP/KT205A Size:

AT19 x 10-9 Type:

Tubeless

The tires should be set to the recommend- ed pressure: Recommended tire pressure:

Front: 27.5 kPa (4.0 psi) (0.275 kgf/cm

2

) Rear:

27.5 kPa (4.0 psi) (0.275 kgf/cm

2

)

Check and adjust tire pressures when the tires are cold.

Tire pressures must be equal on both sides.

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EBU19820

Measuring the tire pressure

Use the low-pressure tire gauge.

NOTE:

The low-pressure tire gauge is included as stan- dard equipment. Make two measurements of the tire pressure and use the second reading. Dust or

dirt in the gauge could cause the first reading to be

incorrect.

Set the tire pressure when the tires are cold. Set the tire pressures to the following specifications:

Tire pressure below the minimum speci- fied could cause the tire to dislodge from the rim under severe riding conditions. Minimum tire pressure:

Front: 24.5 kPa (3.5 psi) (0.245 kgf/cm

2

) Rear:

24.5 kPa (3.5 psi) (0.245 kgf/cm

2

)

Use no more than the following pressures when seating the tire beads.

Maximum tire seating pressure: Front:

250 kPa (36 psi) (2.5 kgf/cm

2

) Rear:

250 kPa (36 psi) (2.5 kgf/cm

2

) Higher pressures and fast inflation may cause a tire to burst. Inflate the tires very slowly and carefully.

1. Low-pressure tire gauge

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EBU19830

Tire wear limit

Replace the tire when the tire groove decreases to 3 mm (0.12 in).

EBU19840

Chassis fasteners

Make sure that all nuts, bolts and screws are prop- erly tightened.

EBU19850

Instruments, lights and switches

Check that all instruments, lights and switches are working properly. Correct if necessary.

Recommended pressure: Front

27.5 kPa (4.0 psi) (0.275 kgf/cm

2

) Rear

27.5 kPa (4.0 psi) (0.275 kgf/cm

2

) Minimum:

Front 24.5 kPa (3.5 psi) (0.245 kgf/cm

2

) Rear

24.5 kPa (3.5 psi) (0.245 kgf/cm

2

) Maximum:

Front 30.5 kPa (4.4 psi) (0.305 kgf/cm

2

) Rear

30.5 kPa (4.4 psi) (0.305 kgf/cm

2

)

1. Tire wear limit

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EBU19870

OPERATION

WARNING

EWB00010

Indicates a potential hazard that could result in serious injury or death.

EBU19890

EWB00610

EBU20091

Starting a cold engine

EWB00620

CAUTION:

ECB00150

See the Engine break-in section on page 6-5

prior to operating the engine for the first time.

1. Set the parking brake. 2. Turn the fuel cock to ON. 3. Turn the main switch to ON and the engine

stop switch to RUN. 4. Shift the transmission into neutral. The neutral

indicator light should come on. If the indicator

WARNING

POTENTIAL HAZARD Operating ATV without being familiar with all controls. WHAT CAN HAPPEN Loss of control, which could cause an acci- dent or injury. HOW TO AVOID THE HAZARD Read the Owners Manual carefully. If there is a control or function you do not understand, ask your Yamaha dealer.

WARNING

POTENTIAL HAZARD Frozen control cables in cold weather. WHAT CAN HAPPEN You could be unable to control the ATV, which could lead to an accident or collision. HOW TO AVOID THE HAZARD When riding in cold weather, always make sure all control cables work smoothly before you begin riding.

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light does not come on, have a Yamaha deal- er check the electrical circuit.

NOTE:

This model is equipped with an ignition circuit cut- off system. The engine can be started under the following conditions.

The transmission is in neutral.

The clutch is disengaged with the transmission in gear. However, it is recommended to shift into

neutral before starting the engine.

5. Use the starter (choke) in reference to the fig- ure:

Position (1):

Cold engine start with ambient temperature be- low 5 C (40 F).

Position (2):

Cold engine start with ambient temperature be- tween 0 C (30 F) and 30 C (90 F).

Position (3):

Cold engine start with ambient temperature above 25 C (80 F).

Ambient temp./starter (choke) position

6. Completely close the throttle lever and start the engine by pushing the start switch.

NOTE:

If the engine fails to start, release the start switch, then push it again. Pause a few seconds before the next attempt. Each cranking should be as short as possible to preserve battery energy. Do not crank the engine more than 10 seconds on each

1. Fully open 2. Half open 3. Closed 4. Starter (choke)

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attempt.

7. If the engine is started with the starter (choke) in position (1), the starter (choke) should be returned to position (2) to warm up the engine. If the engine is started with the starter (choke) in position (2), keep the starter (choke) in this position to warm up the engine.

CAUTION:

ECB00160

For maximum engine life, always warm the en- gine up before starting off. Never accelerate

hard when the engine is cold!

8. Continue warming up the engine until it idles smoothly, then return the starter (choke) to position (3) before riding.

NOTE:

The engine is warm when it responds normally to

the throttle with the starter (choke) turned off.

EBU20291

Starting a warm engine

Follow the same procedure as for starting a cold engine, with the exception that the starter (choke) is not required when the engine is warm. Instead, start the engine with the throttle slightly open.

EBU20520

Shifting

This ATV has a 5-speed forward transmission. The transmission allows you to control the amount of power you have available at a given speed or for starting, accelerating, climbing hills, etc. To shift into neutral, return the throttle lever to the closed position, apply the clutch, and then repeat- edly depress the shift pedal until it stops. When it stops, it will be in first gear. Raise the pedal slightly to reach the neutral position.

1. Shift pedal 2. Neutral position

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EBU20560

To start out and accelerate

1. Release the throttle lever.

CAUTION:

ECB00200

Always close the throttle before shifting gears, otherwise damage to the engine and drive train

may result.

2. Pull the clutch lever to disengage the clutch. 3. Shift into first gear. 4. Open the throttle gradually and at the same

time, release the clutch lever slowly. 5. Once the ATV has attained adequate speed,

release the throttle, and at the same time, quickly pull in the clutch lever.

6. Shift the transmission into second gear. (Make sure not to shift the transmission into neutral)

7. Open the throttle part way and gradually re- lease the clutch lever.

8. Follow the same procedure when shifting to the next higher gear.

EWB00680

EBU20640

To decelerate

When slowing down or stopping, release the throt- tle and apply the brakes smoothly and evenly. As you slow down, shift to a lower gear. Be sure that the engine has sufficiently slowed before engaging a lower gear. Improper use of the brakes or shifting can cause the tires to lose traction, reducing con- trol and increasing the possibility of an accident.

EWB00650

WARNING

POTENTIAL HAZARD Opening the throttle abruptly or releasing the clutch lever too quickly. WHAT CAN HAPPEN The ATV could wheelie. This would increase the chance of an accident, including over- turn. HOW TO AVOID THE HAZARD Open the throttle gradually. Release the clutch lever gradually.

WARNING

POTENTIAL HAZARD Engaging a lower gear when the engine speed is too high.

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CAUTION:

ECB00180

Even with the transmission in the neutral po- sition, do not coast for long periods of time with the engine off, and do not tow the ATV for long distances. The transmission is prop- erly lubricated only when the engine is run- ning. Inadequate lubrication may damage the transmission.

Always use the clutch when changing gears. The engine, transmission and drive train are not designed to withstand the shock of forced shifting and can be damaged by shift-

ing without using the clutch.

EBU20672

Engine break-in

NOTE:

For ATVs equipped with an odometer or an hour meter, follow the figures given in km (mi) or the figures given in hours.

For ATVs not equipped with an odometer or

hour meter, follow the figures given in hours.

There is never a more important period in the life of your engine than the first 320 km (200 mi) or 20 hours of riding. For this reason, you should read the following material carefully. Since the engine is brand new, do not put an ex- cessive load on it for the first 320 km (200 mi) or 20 hours. The various parts in the engine wear and polish themselves to the correct operating clear- ances. During this period, prolonged full-throttle operation or any condition that might result in en- gine overheating must be avoided.

0160 km (0100 mi) or 010 hours

Avoid prolonged operation above 1/2 throttle. Vary the speed of the ATV regularly. Do not operate it at one set throttle position.

WHAT CAN HAPPEN The wheels could stop rotating and lose trac- tion. This could cause loss of control, an ac- cident and injury. It could also cause engine or drive train damage. HOW TO AVOID THE HAZARD Make sure the engine has sufficiently slowed before shifting to a lower gear.

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160320 km (100200 mi) or 1020 hours

Avoid prolonged operation above 3/4 throttle. Rev the engine through the gears freely, but do not use full throttle at any time.

320 km (200 mi) or 20 hours and beyond

The ATV can now be operated normally.

CAUTION:

ECB00220

If any engine trouble should occur during the engine break-in period, immediately have a

Yamaha dealer check the ATV.

EBU20721

Parking

When parking the ATV, stop the engine, shift into first gear, apply the parking brake, and then turn the fuel cock to OFF.

EBU20850

Parking on a slope

EWB00790

1. Locked position

WARNING

POTENTIAL HAZARD Parking on a hill or other incline. WHAT CAN HAPPEN The ATV could roll out of control, increasing the chance of an accident.

1

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1. Bring the ATV to a stop by applying the brakes in first gear.

2. Stop the engine and release the clutch lever. 3. With the rear brake applied, apply the parking

brake and slowly release the brake pedal.

EBU20910

Accessories and loading

EBU20920

Accessories

Accessories can affect the handling and control of your ATV. Keep the following in mind when consid- ering an accessory or operating an ATV which has accessories.

Choose only accessories designed for your ATV. Your Yamaha dealer has a variety of gen- uine Yamaha accessories. Other accessories may also be available on the market. However, it is not possible for Yamaha to test all non- Yamaha accessories, nor control over their qual- ity or suitability. Choose a genuine Yamaha ac- cessory, or one that is equivalent in design and quality.

Accessories should be rigidly and securely mounted. An accessory which can shift position or come off while you are riding could affect your ability to control the ATV.

Do not mount an accessory where it could inter- fere with your ability to control the ATV. Exam- ples include (but are not limited to) a heavy or bulky object attached to the handlebars which could make steering difficult, an accessory that

HOW TO AVOID THE HAZARD Avoid parking on hills or other inclines. If you must park on an incline, place the ATV trans- versely across the incline, shift into first gear, stop the engine, apply the parking brake, and then block the front and rear wheels with rocks or other objects. Do not park the ATV at all on hills that are so steep you could not walk up them easily.

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limits your ability to move around on the seat, or one that limits your view.

Use extra caution when riding an ATV with ac- cessories. The ATV may handle differently than it does without accessories.

EBU20930

Loading

As originally equipped, this ATV is not designed to carry cargo or tow a trailer. If you choose to add ac- cessories so that you can carry cargo or tow a trail- er, you must use common sense and good judgment as the stability and handling of an ATV can be changed. When adding accessories, keep the following points in mind:

Never exceed the weight limits shown. An over- loaded ATV can be unstable.

If you are carrying cargo and towing a trailer, in- clude the tongue weight in the maximum ATV load limit.

Load cargo on the carriers as close to the center

of the ATV as possible. Put cargo at the rear of the front carrier, at the front of the rear carrier, and center it.

Tie down cargo securely to the carriers. Make sure cargo in the trailer cannot move around. A shifting load can cause an accident.

Make sure the load does not interfere with con- trols or your ability to see where you are going.

Ride more slowly than you would without a load. The more weight you carry, the slower you should go. Although conditions vary, it is good practice not to exceed 2nd gear whenever you are carrying heavier loads or when towing a trail- er.

Allow more braking distance. A heavier ATV takes longer to stop.

Avoid making sharp turns unless at very slow speeds.

Avoid hills and rough terrain. Choose terrain carefully. Added weight affects the stability and handling of the ATV.

EWB00750

MAXIMUM LOADING LIMIT ATV loading limit (total weight of rider, cargo, accessories, and tongue):

100.0 kg (220 lb)

WARNING

POTENTIAL HAZARD Overloading this ATV or carrying or towing cargo improperly.

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WARNING

EWB00010

Indicates a potential hazard that could result in serious injury or death.

WHAT CAN HAPPEN Could cause changes in ATV handling which could lead to an accident. HOW TO AVOID THE HAZARD Never exceed the stated load capacity for this ATV. Cargo should be properly distributed and se- curely attached. Reduce speed when carrying cargo or pull- ing a trailer. Allow greater distance for brak- ing.

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EBU21131

RIDING YOUR ATV

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WARNING

EWB00010

Indicates a potential hazard that could result in serious injury or death.

EBU21591

GETTING TO KNOW YOUR ATV

This ATV is intended for recreational use by expe- rienced operators only. Even if you are an experi- enced operator of all other all terrain ATVs or motorcycles, riding the ATV requires special skills acquired through practice. Take your time to fully learn techniques before attempting more difficult maneuvers. Riding your new ATV can be a very enjoyable ac- tivity, providing you with hours of pleasure. But it is essential to familiarize yourself with the operation of the ATV to achieve the skill necessary to enjoy riding safely. Before you begin to ride, be sure you have read this Owners Manual completely and un- derstand the operation of the controls. Pay partic- ular attention to the safety information on pages 1-11-5. Please also read all caution and warning labels on your ATV.

RIDE WITH CARE AND GOOD JUDGEMENT

Get training if you are inexperienced.

Beginners should get training from a certified in- structor. Become familiar with this ATV at slow speeds first, even if you are an experienced operator. Do not at- tempt to operate at maximum performance until you are totally familiar with the ATVs handling and performance characteristics.

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EWB01280

Riding your ATV requires skills acquired through practice over a period of time.

Take the time to learn the basic techniques well before attempting more difficult maneuvers.

Not recommended for children under 16 years of age.

EWB00901

WARNING

POTENTIAL HAZARD Operating this ATV without proper instruc- tion. WHAT CAN HAPPEN The risk of an accident is greatly increased if the operator does not know how to operate the ATV properly in different situations and on different types of terrain. HOW TO AVOID THE HAZARD Beginning and inexperienced operators should complete the certified training course offered by Yamaha. They should then regu- larly practice the skills learned in the course and the operating techniques described in this Owners Manual. For more information about the training course, contact an autho- rized ATV dealer or call 1-800-887-2887.

WARNING

POTENTIAL HAZARD Failure to follow the age recommendations for this ATV. WHAT CAN HAPPEN Use by children of ATVs that are not recom- mended for their age can lead to severe inju- ry or death of the child. HOW TO AVOID THE HAZARD A child under 16 should never operate an ATV with engine size greater than 90 cc.

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This ATV is designed to carry operator only passengers prohibited.

EWB00910

WARNING

POTENTIAL HAZARD Carrying a passenger on this ATV. WHAT CAN HAPPEN Greatly reduces your ability to balance and control this ATV. Could cause an accident, resulting in harm to you and/or your passen- ger. HOW TO AVOID THE HAZARD Never carry a passenger. The long seat is to allow the operator to shift position as needed during operation. It is not for carrying pas- sengers.

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Apparel

EWB00920

WARNING

POTENTIAL HAZARD Operating this ATV without wearing an ap- proved motorcycle helmet, eye protection and protective clothing. WHAT CAN HAPPEN Operating without an approved motorcycle helmet increases your chances of a severe head injury or death in the event of an acci- dent. Operating without eye protection can result in an accident and increases your chances of a severe injury in the event of an accident. Operating without protective clothing in- creases your chances of severe injury in the event of an accident.

HOW TO AVOID THE HAZARD Always wear an approved motorcycle helmet that fits properly. You should also wear:

eye protection (goggles or face shield)

gloves

boots

long-sleeved shirt or jacket

long pants

1. Protective clothing 2. Goggles 3. Gloves 4. Boots 5. Helmet

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Do not operate after consuming alcohol or drugs.

The operators performance capability is reduced by the influence of alcohol or drugs.

EWB00930

Pre-operation checks

Always perform the pre-operation checks listed on page 5-1 before riding for proper care of the ATV and to ensure safety.

WARNING

POTENTIAL HAZARD Operating this ATV after consuming alcohol or drugs. WHAT CAN HAPPEN Could seriously affect your judgment. Could cause you to react more slowly. Could affect your balance and perception. Could result in an accident.

HOW TO AVOID THE HAZARD Never consume alcohol or drugs before or while driving this ATV.

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EWB00940

EWB00950

WARNING

EWB00010

Indicates a potential hazard that could result in serious injury or death.

Do not operate at speeds too fast for your skills or the conditions.

EWB00960

WARNING

POTENTIAL HAZARD Failure to inspect the ATV before operating. Failure to properly maintain the ATV. WHAT CAN HAPPEN Increases the possibility of an accident or equipment damage. HOW TO AVOID THE HAZARD Always inspect your ATV each time you use it to make sure the ATV is in safe operating condition. Always follow the inspection and mainte- nance procedures and schedules described in the Owners Manual.

WARNING

POTENTIAL HAZARD Operating this ATV with improper tires, or with improper or uneven tire pressure. WHAT CAN HAPPEN Use of improper tires on this ATV, or opera- tion of this ATV with improper or uneven tire pressure, may cause loss of control, increas- ing your risk of an accident.

HOW TO AVOID THE HAZARD Always use the size and type tires specified in the Owners Manual for this ATV on page 5-7. Always maintain proper tire pressure as de- scribed in the Owners Manual on page 5-8.

WARNING

POTENTIAL HAZARD Operating this ATV at speeds too fast for your skills or the conditions. WHAT CAN HAPPEN Increases your chances of losing control of the ATV, which can result in an accident. HOW TO AVOID THE HAZARD Always go at a speed that is proper for the terrain, visibility and operating conditions, and your experience.

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Speed limiter

For riders less experienced with this model, the throttle lever housing is equipped with a speed lim- iter. The speed limiter keeps the throttle from fully opening, even when the throttle lever is pushed to the maximum. Turning in the adjusting screw limits the maximum engine power available and de- creases the maximum speed of the ATV. Turning in the adjusting screw decreases top speed, and turning it out increases top speed. (See page 4-4.)

Loading and accessories

As originally equipped, this ATV is not designed to

carry cargo or tow a trailer. If you choose to add ac- cessories so that you can carry cargo or tow a trail- er, you must use common sense and good judgment. Use extra caution when riding the ATV with addi- tional loads, such as accessories or cargo. The ATVs handling may be adversely affected. Re- duce your speed when adding additional loads.

1. Adjusting screw 2. Locknut

2 1

MAXIMUM LOADING LIMIT ATV loading limit (total weight of cargo, rider, accessories, and tongue):

100.0 kg (220 lb)

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EWB00970

During operation

Always keep your feet on the footboards during op- eration, otherwise they may contact the rear wheels.

EWB00980

WARNING

POTENTIAL HAZARD Overloading this ATV or carrying or towing cargo improperly. WHAT CAN HAPPEN Could cause changes in ATV handling which could lead to an accident. HOW TO AVOID THE HAZARD Never exceed the stated load capacity for this ATV. Cargo should be properly distributed and se- curely attached. Reduce speed when carrying cargo or pull- ing a trailer. Allow greater distance for brak- ing. Always follow the instructions in your Own- ers Manual for carrying cargo or pulling a trailer.

WARNING

POTENTIAL HAZARD Removing hands from handlebars or feet from footboards during operation.

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Avoid wheelies and jumping. You may lose control of the ATV or overturn.

EWB00990

WHAT CAN HAPPEN Removing even one hand or foot can reduce your ability to control the ATV or could cause you to lose your balance and fall off of the ATV. If you remove a foot from a footboard, your foot or leg may come into contact with the rear wheels, which could injure you or cause an accident. HOW TO AVOID THE HAZARD Always keep both hands on the handlebars and both feet on the footboards of your ATV during operation.

WARNING

POTENTIAL HAZARD Attempting wheelies, jumps, and other stunts. WHAT CAN HAPPEN Increases the chance of an accident, includ- ing an overturn. HOW TO AVOID THE HAZARD Never attempt stunts, such as wheelies or jumps. Dont try to show off.

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Modifications

EWB01000

Exhaust system

The exhaust system on the ATV is very hot during and following operation. To prevent burns, avoid touching the exhaust system. Park the ATV in a place where pedestrians or children are not likely

to touch it.

EWB01010

WARNING

POTENTIAL HAZARD Operating this ATV with improper modifica- tions. WHAT CAN HAPPEN Improper installation of accessories or mod- ification of this ATV may cause changes in handling which in some situations could lead to an accident. HOW TO AVOID THE HAZARD Never modify this ATV through improper in- stallation or use of accessories. All parts and accessories added to this ATV should be genuine Yamaha or equivalent components designed for use on this ATV and should be installed and used according to instructions. If you have questions, consult an authorized ATV dealer.

WARNING

POTENTIAL HAZARD Hot exhaust system. WHAT CAN HAPPEN Dry grass or brush or other combustible ma- terial accumulated around the engine area could catch fire. Someone touching the exhaust system dur- ing or after operation could be burned. HOW TO AVOID THE HAZARD Do not operate, idle, or park the ATV in dry grass or other dry ground cover. Keep the engine area free of dry grass, brush, or other combustible material. Do not touch the hot exhaust system. Do not park the ATV in a place where others might be likely to touch it.

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BE CAREFUL WHERE YOU RIDE

This ATV is designed for off-road use only. Riding on paved surfaces can cause loss of control.

EWB01020

Do not ride on any public road, street, or highway. Riding on public roads can result in collisions with other vehicles.

WARNING

POTENTIAL HAZARD Operating this ATV on paved surfaces. WHAT CAN HAPPEN ATVs are designed for off-road use only. Paved surfaces may seriously affect han- dling and control of the ATV, and may cause the ATV to go out of control. HOW TO AVOID THE HAZARD Always avoid paved surfaces, including side- walks, driveways, parking lots and streets.

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EWB01030

Know the terrain where you ride. Ride cautiously in unfamiliar areas. Stay alert for

holes, rocks, or roots

in the terrain, and

other hidden hazards

which may cause the ATV to upset.

EWB01040

WARNING

POTENTIAL HAZARD Operating this ATV on public streets, roads or highways. WHAT CAN HAPPEN You can collide with another vehicle. HOW TO AVOID THE HAZARD Never operate this ATV on any public street, road or highway, even a dirt or gravel one. In many states it is illegal to operate ATVs on public streets, roads and highways.

WARNING

POTENTIAL HAZARD Failure to use extra care when operating this ATV on unfamiliar terrain.

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EWB01050

WHAT CAN HAPPEN You can come upon hidden rocks, bumps, or holes, without enough time to react. Could result in the ATV overturning or going out of control. HOW TO AVOID THE HAZARD Go slowly and be extra careful when operat- ing on unfamiliar terrain. Always be alert to changing terrain conditions when operating the ATV.

WARNING

POTENTIAL HAZARD Failure to use extra care when operating on excessively rough, slippery or loose terrain. WHAT CAN HAPPEN Could cause loss of traction or ATV control, which could result in an accident, including an overturn. HOW TO AVOID THE HAZARD Do not operate on excessively rough, slip- pery or loose terrain until you have learned and practiced the skills necessary to control the ATV on such terrain. Always be especial- ly cautious on these kinds of terrain.

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When riding in an area where you might not easily be seen, such as desert terrain, mount a caution flag on the ATV. DO NOT use the flag pole bracket as a trailer hitch.

EWB01060

WARNING

POTENTIAL HAZARD Operating in areas where you might not be seen by other off-road vehicles. WHAT CAN HAPPEN You could be in a collision. You could be in- jured. HOW TO AVOID THE HAZARD Always mount a caution flag on the ATV to make you more visible. Watch carefully for other vehicles.

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Do not ride in areas posted no trespassing. Do not ride on private property without getting per- mission.

Select a large, flat area off-road to become familiar with your ATV. Make sure that this area is free of obstacles and other riders. You should practice control of the throttle, brakes, shifting procedures, and turning techniques in this area before trying more difficult terrain. Always avoid riding on paved surfaces: the ATV is designed for off-road use only, and handling maneuvers are more difficult to perform on pavement. Set the parking brake and follow the instruction on page 6-1 to start the engine. Once it has warmed up you are ready to begin riding your ATV. As you get on the ATV, be sure not to accidentally move

the shift pedal. Remember that the engine and ex- haust pipe will be hot when riding and afterwards; do not allow skin or clothing to come in contact with these components. With the engine idling, pull the clutch lever to dis- engage the clutch and shift into 1st gear, and then release the parking brake. Open the throttle grad- ually, and at the same time, release the clutch le- ver slowly. Once the ATV has attained adequate speed, release the throttle lever and at the same time, quickly pull in the clutch lever and shift into 2nd gear. Open the throttle part way and gradually release the clutch. Use this same procedure as you move into the higher gears. Be sure to coordi- nate the use of the throttle and shift pedal properly. If the throttle is applied too abruptly or if the throttle is not released during shifting, or if the shift pedal is not released before applying the throttle, the front wheels may lift off the ground, resulting in a loss of directional control. Avoid higher speeds un- til you are thoroughly familiar with the operation of your ATV.

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EWB01240

CAUTION:

ECB00230

Do not shift gears without releasing the throt- tle. Damage to the engine or drive train may oc-

cur.

When slowing down or stopping, release the throt- tle and apply the brakes smoothly and evenly. As you slow down, shift to a lower gear. Be sure that the engine has sufficiently slowed before engaging a lower gear. Improper use of the brakes or shifting can cause the tires to lose traction, reducing con- trol and increasing the possibility of an accident.

EWB01070

TURNING YOUR ATV

To achieve maximum traction while riding off-road, the two rear wheels are mounted solidly on one axle and turn together at the same speed. There- fore, unless the wheel on the inside of the turn is al- lowed to slip or lose some traction, the ATV will resist turning. A special turning technique must be used to allow the ATV to make turns quickly and easily. It is essential that this skill be learned first at low speed.

WARNING

POTENTIAL HAZARD Opening the throttle abruptly or releasing the clutch lever too quickly. WHAT CAN HAPPEN The ATV could wheelie. This would increase the chance of an accident, including over- turn. HOW TO AVOID THE HAZARD Open the throttle gradually. Release the clutch lever gradually.

WARNING

POTENTIAL HAZARD Engaging a lower gear when the engine speed is too high. WHAT CAN HAPPEN The wheels could stop rotating. This could cause loss of control, an accident and injury. It could also cause engine or drive train dam- age. HOW TO AVOID THE HAZARD Make sure the engine has sufficiently slowed before shifting to a lower gear.

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EWB01220

As you approach a curve, slow down and begin to turn the handlebars in the desired direction. As you do so, put your weight on the footboard to the out- side of the turn (opposite your desired direction) and lean your upper body into the turn. Use the throttle to maintain an even speed through the turn. This maneuver will let the wheel on the inside of the turn slip slightly, allowing the ATV to make the turn properly.

This procedure should be practiced at slow speed many times in a large off-road area with no obsta- cles. If an incorrect technique is used, your ATV may continue to go straight. If the ATV doesnt turn, come to a stop and then practice the proce- dure again. If the riding surface is slippery or loose, it may help to position more of your weight over the front wheels by moving forward on the seat. Once you have learned this technique, you should be able to perform it at higher speeds or in tighter

WARNING

POTENTIAL HAZARD Turning improperly. WHAT CAN HAPPEN The ATV could go out of control, causing a collision or overturn. HOW TO AVOID THE HAZARD Always follow proper procedures for turning as described in this Owners Manual. Prac- tice turning at low speeds before attempting to turn at faster speeds. Do not turn at speeds too fast for your skills or the condi- tions.

1. Lean towards inside of turn. 2. Support your weight on the outer footrest.

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curves. Improper riding procedures such as abrupt throttle changes, excessive braking, incorrect body move- ments, or too much speed for the sharpness of the turn may cause the ATV to tip. If the ATV begins to tip over to the outside while negotiating a turn, lean more to the inside. It may also be necessary to gradually let off on the throttle and steer to the out- side of the turn to avoid tipping over. Remember: Avoid higher speeds until you are thoroughly familiar with the operation of your ATV.

CLIMBING UPHILL

Use proper riding techniques to avoid ATV over- turns on hills. Be sure that you can maneuver your ATV well on flat ground before attempting any in- cline and then practice riding first on gentle slopes. Try more difficult climbs only after you have devel- oped your skill. In all cases avoid inclines with slip- pery or loose surfaces, or obstacles that might cause you to lose control.

EWB01090

It is important when climbing a hill to make sure that your weight is transferred forward on the ATV. This can be accomplished by leaning forward and, on steeper inclines, standing on the footboards and leaning forward over the handlebars.

EWB01100

WARNING

POTENTIAL HAZARD Operating on excessively steep hills.

WHAT CAN HAPPEN The ATV can overturn more easily on ex- tremely steep hills than on level surfaces or small hills. HOW TO AVOID THE HAZARD Never operate the ATV on hills too steep for the ATV or for your abilities. Practice on smaller hills before attempting large hills.

WARNING

POTENTIAL HAZARD Climbing hills improperly. WHAT CAN HAPPEN Could cause loss of control or cause the ATV to overturn.

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If you are climbing a hill and you find that you have not properly judged your ability to make it to the top, you should turn the ATV around while you still have forward motion (provided you have the room to do so) and go down the hill.

HOW TO AVOID THE HAZARD Always follow proper procedures for climb- ing hills as described in this Owners Manual. Always check the terrain carefully before you start up any hill. Never climb hills with excessively slippery or loose surfaces. Shift your weight forward. Never open the throttle suddenly or make sudden gear changes. The ATV could flip over backwards. Never go over the top of any hill at high speed. An obstacle, a sharp drop, or another vehicle or person could be on the other side of the hill.

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EWB01190

If your ATV has stalled or stopped and you believe you can continue up the hill, restart carefully to make sure you do not lift the front wheels which could cause you to lose control. If you are unable to continue up the hill, dismount the ATV on the up- hill side. Physically turn the ATV around and then descend the hill. If you start to roll backwards, DO NOT apply the rear brake to stop or try to put the ATV in gear. The ATV could easily tip over backwards. Instead, ap- ply the front brake gradually, or dismount the ATV

WARNING

POTENTIAL HAZARD Improperly crossing hills or turning on hills. WHAT CAN HAPPEN Could cause loss of control or cause the ATV to overturn. HOW TO AVOID THE HAZARD Never attempt to turn the ATV around on any hill until you have mastered the turning tech- nique as described in the Owners Manual on level ground. Be very careful when turning on any hill. Avoid crossing the side of a steep hill if pos- sible. When crossing the side of a hill: Always follow proper procedures as de- scribed in the Owners Manual. Avoid hills with excessively slippery or loose surfaces. Shift your weight to the uphill side of the ATV.

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immediately on the uphill side.

EWB01251

RIDING DOWNHILL

When riding your ATV downhill, shift your weight as far to the rear and uphill side of the ATV as pos- sible. Move back on the seat and sit with your arms straight. Choose a low gear which will allow the en- gine compression to do most of the braking for you. Improper braking may cause a loss of trac- tion. Use caution while descending a hill with loose or slippery surfaces. Braking ability and traction may be adversely affected by these surfaces. Improper

WARNING

POTENTIAL HAZARD Stalling, rolling backwards or improperly dis- mounting while climbing a hill. WHAT CAN HAPPEN Could result in the ATV overturning. HOW TO AVOID THE HAZARD Use the proper gear and maintain a steady speed when climbing a hill. If you lose all forward speed:

Keep weight uphill.

Apply the brakes.

Lock the parking brake after you are stopped.

If you begin rolling backwards:

Keep weight uphill.

Never apply the rear brake while rolling backwards. Apply the front brake.

When fully stopped, apply the rear brake as well, and then lock the parking brake.

Dismount on uphill side or to a side if pointed straight uphill. Turn the ATV around and re- mount, following the procedure described in the Owners Manual.

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braking may also cause a loss of traction. Whenever possible, ride your ATV straight down- hill. Avoid sharp angles which could allow the ATV to tip or roll over. Carefully choose your path and ride no faster than you will be able to react to ob- stacles which may appear.

EWB01130

WARNING

POTENTIAL HAZARD Going down a hill improperly. WHAT CAN HAPPEN Could cause loss of control or cause the ATV to overturn.

HOW TO AVOID THE HAZARD Always follow proper procedures for going down hills as described in this Owners Man- ual. Note: a special technique is required when braking as you go down a hill. Always check the terrain carefully before you start down any hill. Shift your weight backward. Never go down a hill at high speed. Avoid going down a hill at an angle that would cause the ATV to lean sharply to one side. Go straight down the hill where possi- ble.

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CROSSING A SLOPE

Traversing a sloping surface on your ATV requires you to properly position your weight to maintain proper balance. Be sure that you have learned the basic riding skills on flat ground before attempting to cross a sloping surface. Avoid slopes with slip- pery surfaces or rough terrain that may upset your balance. As you travel across a slope, lean your body in the uphill direction. It may be necessary to correct the

steering when riding on loose surfaces by pointing the front wheels slightly uphill. When riding on slopes, be sure not to make sharp turns either up or down hill. If your ATV does begin to tip over, gradually steer in the downhill direction if there are no obstacles in your path. As you regain proper balance, gradually steer again in the direction you wish to travel.

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EWB01141

CROSSING THROUGH SHALLOW WATER

The ATV can be used to cross slow moving, shal- low water of up to a maximum of 35 cm (14 in) in depth. Before entering the water, choose your path carefully. Enter where there is no sharp drop off, and avoid rocks or other obstacles which may be slippery or upset the ATV. Drive slowly and care- fully.

WARNING

POTENTIAL HAZARD Improperly crossing hills or turning on hills. WHAT CAN HAPPEN Could cause loss of control or cause the ATV to overturn. HOW TO AVOID THE HAZARD Never attempt to turn the ATV around on any hill until you have mastered the turning tech- nique as described in the Owners Manual on level ground. Be very careful when turning on any hill. Avoid crossing the side of a steep hill if possible. When crossing the side of a hill: Always follow proper procedures as de- scribed in the Owners Manual. Avoid hills with excessively slippery or loose surfaces. Shift your weight to the uphill side of the ATV.

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EWB01150

Test your brakes after leaving the water. Do not continue to ride your ATV without verifying that you have regained proper braking ability.

WARNING

POTENTIAL HAZARD Operating this ATV through deep or fast flowing water. WHAT CAN HAPPEN Tires may float, causing loss of traction and loss of control, which could lead to an acci- dent. HOW TO AVOID THE HAZARD Never operate this ATV in fast flowing water or in water deeper than that specified in your Owners Manual. Remember that wet brakes may have re- duced stopping ability. Test your brakes af- ter leaving water. If necessary, apply them several times to let friction dry out the lin- ings.

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CAUTION:

ECB00240

After riding your ATV in water, be sure to drain the trapped water by removing the check hose at the bottom of the air filter case. Wash the ATV in fresh water if it has been operated in

salt water or muddy conditions.

RIDING OVER ROUGH TERRAIN

Riding over rough terrain should be done with cau- tion. Look out for obstacles which could cause damage to the ATV or could lead to an upset or ac- cident. Be sure to keep your feet firmly mounted on the footboards at all times. Avoid jumping the ATV as loss of control and damage to the ATV may re- sult.

EWB01160

1. Air lter case check hose

WARNING

POTENTIAL HAZARD Improperly operating over obstacles.

1

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SLIDING AND SKIDDING

Care should be used when riding on loose or slip- pery surfaces since the ATV may slide. If unex- pected and uncorrected, sliding could lead to an accident. To reduce the tendency for the front wheels to slide in loose or slippery conditions, positioning your weight over the front wheels will sometimes help.

If the rear wheels of your ATV start to slide side- ways, control can usually be regained (if there is room to do so) by steering in the direction of the slide. Applying the brakes or accelerating is not recommended until you have corrected the slide.

WHAT CAN HAPPEN Could cause loss of control or a collision. Could cause the ATV to overturn. HOW TO AVOID THE HAZARD Before operating in a new area, check for ob- stacles. Never attempt to ride over large obstacles, such as large rocks or fallen trees. When you go over obstacles, always follow proper pro- cedures as described in the Owners Manual.

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With practice, over a period of time, skill at con- trolled sliding can be developed. The terrain should be chosen carefully before attempting such maneuvers, since both stability and control are re- duced. Bear in mind that sliding maneuvers should always be avoided on extremely slippery surfaces such as ice, since all control may be lost.

EWB01170

WHAT TO DO IF...

This section is designed to be a reference guide only. Be sure to read each section on riding tech- niques completely.

WHAT TO DO...

If your ATV doesnt turn when you want it to: Bring the ATV to a stop and practice the turning maneuvers again. Be sure you are putting your weight on the footboard to the outside of the turn. Position your weight over the front wheels for better control. (See page 7-17.)

If your ATV begins to tip while turning:

WARNING

POTENTIAL HAZARD Skidding or sliding improperly.

WHAT CAN HAPPEN You may lose control of this ATV. You may also regain traction unexpectedly, which may cause the ATV to overturn. HOW TO AVOID THE HAZARD Learn to safely control skidding or sliding by practicing at low speeds and on level, smooth terrain. On extremely slippery surfaces, such as ice, go slowly and be very cautious in order to re- duce the chance of skidding or sliding out of control.

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Lean more into the turn to regain balance. If nec- essary, gradually let off the throttle and/or steer to the outside of the turn. (See page 7-17.)

If your ATV starts to slide sideways: Steer in the direction of the slide if you have the room. Applying the brakes or accelerating is not recommended until you have corrected the slide. (See page 7-28.)

If your ATV cant make it up a hill you are trying to climb: Turn the ATV around if you still have forward speed. If not, stop, dismount on the uphill side of the ATV and physically turn the ATV around. If the ATV starts to slip backwards, DO NOT USE THE REAR BRAKE the ATV may tip over on top of you. Dismount the ATV on the uphill side. (See page 7-19.)

If your ATV is traversing a sloping surface: Be sure to ride with your weight positioned to- wards the uphill side of the ATV to maintain proper balance. If the ATV starts to tip, steer down the hill (if there are no obstacles in your way) to regain balance. If you discover that the ATV is going to tip over, dismount on the uphill side. (See page 7-19.)

If your ATV encounters shallow water:

Ride slowly and carefully through slow moving water, watching for obstacles. Be sure to let wa- ter drain from the ATV and CHECK YOUR BRAKES FOR PROPER OPERATION when you come out of the water. Do not continue to ride your ATV until you have regained adequate braking ability. (See page 7-25.)

WARNING

EWB00010

Indicates a potential hazard that could result in serious injury or death.

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EBU21647

PERIODIC MAINTENANCE AND MINOR REPAIR

EBU21660

Safety is an obligation of the owner. Periodic in- spection, adjustment and lubrication will keep your ATV in the safest and best operating condition possible. The most important points of inspection, adjustment, and lubrication are explained on the following pages. The intervals given in the periodic maintenance and lubrication chart should be considered as a general guide under normal riding conditions. However, DEPENDING ON THE WEATHER, TERRAIN, GEOGRAPHICAL LOCATION, AND INDIVIDUAL USE, THE MAINTENANCE INTER- VALS MAY NEED TO BE SHORTENED.

EWB01820

EBU21720

Owners manual and tool kit

Be sure to put this owners manual in the plastic bag and always carry it on the bottom of the seat as shown. Put the owners tool kit and low-pres- sure tire gauge under the seat.

WARNING

POTENTIAL HAZARD Servicing an engine while it is running. WHAT CAN HAPPEN Moving parts can catch clothing or parts of the body, causing injury. Electrical components can cause shocks or start fires.

HOW TO AVOID THE HAZARD Turn off the engine when performing mainte- nance unless otherwise specified. Have a Yamaha dealer perform the service if you are not familiar with maintenance work.

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The service information included in this manual and the tools provided in the owners tool kit are in- tended to assist you in the performance of preven- tive maintenance and minor repairs. However, additional tools such as a torque wrench may be necessary to perform certain maintenance work correctly.

NOTE:

If you do not have the tools or experience required for a particular job, have a Yamaha dealer perform

it for you.

EWB01830

1. Low-pressure tire gauge 2. Owners tool kit 3. Owners manual

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WARNING

POTENTIAL HAZARD Operating this ATV with improper modifica- tions. WHAT CAN HAPPEN Improper installation of accessories or mod- ification of this ATV may cause changes in handling which in some situations could lead to an accident. HOW TO AVOID THE HAZARD Never modify this ATV through improper in- stallation or use of accessories. All parts and accessories added to this ATV should be genuine Yamaha or equivalent components designed for use on this ATV and should be installed and used according to instructions. If you have questions, consult an authorized Yamaha ATV dealer.

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EBU21742

Periodic maintenance chart for the emission control system

NOTE:

For ATVs not equipped with an odometer or an hour meter, follow the month maintenance intervals.

For ATVs equipped with an odometer or an hour meter, follow the km (mi) or hours maintenance inter- vals. However, keep in mind that if the ATV isnt used for a long period of time, the month maintenance intervals should be followed.

Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools,

data and technical skills.

NO. ITEM CHECK OR MAINTENANCE JOB

INITIAL EVERY

Whichev- er comes

rst

month 1 3 6 6 12

km (mi)

320 (200)

1300 (800)

2500 (1600)

2500 (1600)

5000 (3200)

hours 20 80 160 160 320

1

*

Fuel line

Check fuel hoses for cracks or other damage, and replace if necessary.

2 Spark plug

Check condition and clean, regap, or replace if necessary.

3

*

Valves

Check valve clearance and adjust if necessary.

4

*

Carburetor

Check starter (choke) operation and correct if nec- essary.

Check engine idling speed and adjust if neces- sary.

5

*

Crankcase breather system

Check breather hose for cracks or other damage, and replace if necessary.

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6

*

Exhaust system

Check for leakage and replace gasket(s) if neces- sary.

Check for looseness and tighten all screw clamps and joints if necessary.

7 Spark arrester

Clean.

NO. ITEM CHECK OR MAINTENANCE JOB

INITIAL EVERY

Whichev- er comes

rst

month 1 3 6 6 12

km (mi)

320 (200)

1300 (800)

2500 (1600)

2500 (1600)

5000 (3200)

hours 20 80 160 160 320

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EBU21864

General maintenance and lubrication chart

NO. ITEM CHECK OR MAINTENANCE JOB

INITIAL EVERY

Whichev- er comes

rst

month 1 3 6 6 12

km (mi)

320 (200)

1300 (800)

2500 (1600)

2500 (1600)

5000 (3200)

hours 20 80 160 160 320

1 Air lter element

Clean and replace if necessary. Every 2040 hours (more often in wet or dusty areas)

2

*

Clutch

Check operation and adjust if necessary.

3

*

Front brake

Check operation and correct if necessary.

Check uid level and ATV for uid leakage, and correct if necessary.

Replace brake pads. Whenever worn to the limit

4

*

Rear brake

Check operation and correct if necessary.

Check uid level and ATV for uid leakage, and correct if necessary.

Replace brake pads. Whenever worn to the limit

5

*

Brake hoses

Check for cracks or other damage, and replace if necessary.

Replace. Every 4 years

6

*

Parking brake

Check operation and adjust if necessary.

7

*

Wheels

Check runout and for damage, and replace if nec- essary.

8

*

Tires

Check tread depth and for damage, and replace if necessary.

Check air pressure and balance, and correct if necessary.

9

*

Wheel hub bearings

Check for looseness or damage, and replace if necessary.

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10

*

Swingarm pivots

Check operation and for excessive play, and replace bearings if necessary.

Lubricate with lithium-soap-based grease.

11

*

Upper and lower arm pivots

Lubricate with lithium-soap-based grease.

12 Drive chain

Check chain slack and adjust if necessary.

Check rear wheel alignment and correct if necess- sary.

Clean and lubricate.

13

*

Drive chain rollers

Check for wear and replace if necessary.

14

*

Chassis fasteners

Make sure that all nuts, bolts, and screws are properly tightened.

15

*

Shock absorber assemblies

Check operation and correct if necessary.

Check for oil leakage and replace if necessary.

16

*

Rear suspension relay arm and con- necting arm pivot- ing points

Check operation and correct if necessary.

Lubricate with lithium-soap-based grease.

17

*

Steering shaft

Lubricate with lithium-soap-based grease.

18

*

Steering system

Check operation and repair or replace if damaged.

Check toe-in and adjust if necessary.

19

*

Engine mount

Check for cracks or other damage, and replace if necessary.

NO. ITEM CHECK OR MAINTENANCE JOB

INITIAL EVERY

Whichev- er comes

rst

month 1 3 6 6 12

km (mi)

320 (200)

1300 (800)

2500 (1600)

2500 (1600)

5000 (3200)

hours 20 80 160 160 320

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3

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20 Engine oil

Change.

Check ATV for oil leakage, and correct if neces- sary.

21 Engine oil lter ele- ment

Clean or replace if necessary.

22

*

Moving parts and cables

Lubricate.

23

*

Throttle lever hous- ing and cable

Check operation and correct if necessary.

Check throttle cable free play and adjust if neces- sary.

Lubricate throttle lever housing and cable.

24

*

Front and rear brake switches

Check operation and correct if necessary.

25

*

Lights and switches

Check operation and correct if necessary.

Adjust headlight beams.

NO. ITEM CHECK OR MAINTENANCE JOB

INITIAL EVERY

Whichev- er comes

rst

month 1 3 6 6 12

km (mi)

320 (200)

1300 (800)

2500 (1600)

2500 (1600)

5000 (3200)

hours 20 80 160 160 320

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1

2

3

4

5

6

7

8

9

10

11

EBU23070

NOTE:

The air filter needs more frequent service if you are riding in unusually wet or dusty areas.

Hydraulic brake service

Regularly check and, if necessary, correct the brake fluid level.

Every two years replace the internal components of the brake master cylinders and calipers, and change the brake fluid.

Replace the brake hoses every four years and if cracked or damaged.

8-9

1

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3

4

5

6

7

8

9

10

11

WARNING

EWB00010

Indicates a potential hazard that could result in serious injury or death.

EBU23211

Checking the spark plug

The spark plug is an important engine component, which is easy to check. Since heat and deposits will cause any spark plug to slowly erode, the spark plug should be removed and checked in accor- dance with the periodic maintenance and lubrica- tion chart. In addition, the condition of the spark plug can reveal the condition of the engine.

To remove the spark plug

1. Remove the spark plug cap.

2. Remove the spark plug as shown, with the spark plug wrench included in the owners tool kit.

1. Spark plug cap

1

8-10

1

2

3

4

5

6

7

8

9

10

11

To check the spark plug

1. Check that the porcelain insulator around the center electrode of the spark plug is a medi- um-to-light tan (the ideal color when the ATV is ridden normally).

NOTE:

If the spark plug shows a distinctly different color, the engine could be operating improperly. Do not attempt to diagnose such problems yourself. In-

stead, have a Yamaha dealer check the ATV.

2. Check the spark plug for electrode erosion and excessive carbon or other deposits, and

replace it if necessary.

To install the spark plug

1. Measure the spark plug gap with a wire thick- ness gauge and, if necessary, adjust the gap to specification.

1. Spark plug wrench

1

Specified spark plug: NGK/DR7EA

Spark plug gap: 0.60.7 mm (0.0240.028 in)

1. Spark plug cap

8-11

1

2

3

4

5

6

7

8

9

10

11

2. Clean the surface of the spark plug gasket and its mating surface, and then wipe off any grime from the spark plug threads.

3. Install the spark plug with the spark plug wrench, and then tighten it to the specified torque.

NOTE:

If a torque wrench is not available when installing a spark plug, a good estimate of the correct torque is 1/41/2 turn past finger tight. However, the spark plug should be tightened to the specified torque as

soon as possible.

4. Install the spark plug cap.

EBU28881

Engine oil and oil filter element

The engine oil level should be checked before each ride. In addition, the oil must be changed and the oil filter element cleaned at the intervals speci- fied in the periodic maintenance and lubrication chart.

To check the engine oil level

1. Place the ATV on a level surface. 2. Check the engine oil level on a cold engine.

NOTE:

If the engine was started before checking the oil level, be sure to warm up the engine sufficiently, and then wait at least ten minutes until the oil set-

tles for an accurate reading.

3. Remove the engine oil filler cap, and then wipe the dipstick off with a clean rag.

4. Insert the dipstick into the filler hole (without screwing it in), and then remove it again to check the oil level.

Tightening torque: Spark plug:

18 Nm (1.8 mkgf, 13 ftlbf)

8-12

1

2

3

4

5

6

7

8

9

10

11

NOTE:

The engine oil should be between the minimum

and maximum level marks.

5. If the engine oil is at or below the minimum level mark, add sufficient oil of the recom- mended type to raise it to the correct level.

6. Insert the dipstick into the oil filler hole, and then tighten the engine oil filler cap.

To change the engine oil (with or without oil filter element cleaning)

1. Place the ATV on a level surface. 2. Start the engine, warm it up for several min-

utes, and then turn it off. 3. Place an oil pan under the engine to collect

the used oil. 4. Remove the engine oil filler cap, and then re-

move the engine oil drain bolt to drain the oil from the crankcase.

1. Engine oil ller cap 2. Dipstick 3. Maximum level mark 4. Minimum level mark

1

2

3

4

1

1. Engine oil drain bolt

1

8-13

1

2

3

4

5

6

7

8

9

10

11

CAUTION:

ECB00310

When removing the engine oil drain bolt, the compression spring, oil strainer and O-ring will

fall out. Take care not to lose these parts.

NOTE:

Skip steps 59 if the oil filter element is not being

cleaned.

5. Remove the oil filter element cover by remov- ing the bolts, and then remove the oil filter el- ement.

6. Clean the oil filter element with solvent. 7. Check the O-rings for damage and replace it if

necessary.

8. Install the oil filter element and O-ring.

NOTE:

Make sure that the O-ring is properly seated.

9. Install the oil filter element cover by installing the bolts, and then tighten them to the speci- fied torque.

1. Oil lter element cover 2. Bolt

1

2

1. Oil lter element 2. O-ring

1

2 2

8-14

1

2

3

4

5

6

7

8

9

10

11

10. Install the engine oil drain bolt and tighten it to the specified torque.

CAUTION:

ECB00320

Before installing the engine oil drain bolt, be sure to install the O-ring, compression spring

and oil strainer.

11. Add the specified amount of the recommend- ed engine oil, and then install and tighten the engine oil filler cap.

NOTE:

Be sure to wipe off spilled oil on any parts after the

engine and exhaust system have cooled down.

CAUTION:

ECB00300

In order to prevent clutch slippage (since the engine oil also lubricates the clutch), do not mix any chemical additives. Do not use oils with a diesel specification of CD or oils of a higher quality than specified. In addition, do not use oils labeled ENERGY CONSERV- ING II or higher.

Make sure that no foreign material enters the

crankcase.

Tightening torque: Oil filter element cover bolt:

10 Nm (1.0 mkgf, 7.2 ftlbf)

Tightening torque: Engine oil drain bolt:

20 Nm (2.0 mkgf, 14.5 ftlbf)

Recommended oil: See page 10-1.

Oil quantity: Without oil filter element replacement:

1.25 L (1.32 US qt) (1.10 Imp.qt) With oil filter element replacement:

1.35 L (1.43 US qt) (1.19 Imp.qt)

8-15

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3

4

5

6

7

8

9

10

11

12. Start the engine, and then let it idle for several minutes while checking it for oil leakage. If oil is leaking, immediately turn the engine off and check for the cause.

13. Turn the engine off, wait at least ten minutes, and then check the oil level and correct it if necessary.

EBU23692

Cleaning the air filter element

The air filter element should be cleaned at the in- tervals specified in the periodic maintenance and lubrication chart. Clean the air filter element more frequently if you are riding in unusually wet or dusty areas.

NOTE:

There is a check hose at the bottom of the air filter case. If dust or water collects in this hose, empty the hose and clean the air filter element and air fil-

ter case.

1. Remove the seat. (See page 4-12.) 2. Remove the air filter case cover by unhooking

the holders.

1. Air lter case check hose

1

8-16

1

2

3

4

5

6

7

8

9

10

11

3. Loosen the wing bolt. 4. Remove the air filter element together with the

wing bolt and washer.

5. Remove the wing bolt and washer from the air filter element.

6. Remove the sponge material from the air filter element frame.

1. Air lter case cover 2. Air lter case cover holder

1

2

1. Wing bolt 2. Air lter element

12

8-17

1

2

3

4

5

6

7

8

9

10

11

7. Wash the sponge material gently but thor- oughly in solvent.

EWB01900

8. Squeeze the excess solvent out of the sponge material and let it dry.

CAUTION:

ECB00440

Do not twist the sponge material when squeez-

ing it.

9. Check the sponge material and replace it if damaged.

10. Apply Yamaha foam air filter oil or other qual- ity foam air filter oil to the sponge material.

1. Sponge material 2. Air lter element frame

WARNING

POTENTIAL HAZARD Using low-flash-point solvents or gasoline to clean the sponge material. WHAT CAN HAPPEN Low-flash-point solvents or gasoline can catch fire or explode.

12

HOW TO AVOID THE HAZARD Use parts cleaning solvent to clean the sponge material.

8-18

1

2

3

4

5

6

7

8

9

10

11

NOTE:

The sponge material should be wet but not drip-

ping.

11. Pull the sponge material over the air filter ele- ment frame.

12. Install the washer onto the air filter element frame, and then insert the wing bolt into the hole in the air filter element frame.

CAUTION:

ECB00451

Be sure to install the washer with the bent edge

facing outward as shown.

13. Insert the air filter element into the air filter case, and then tighten the wing bolt.

14. Install the air filter case cover by hooking the holders onto the air filter case.

15. Install the seat.

NOTE:

The air filter element should be cleaned every 20 40 hours. It should be cleaned and lubricated more often if the ATV is operated in extremely dusty ar- eas. Each time the air filter element maintenance is performed, check the air inlet of the air filter case for obstructions. Check the air filter case rubber joint to the carburetor fittings and the rubber joint manifold fittings for an air-tight seal. Tighten all fit- tings securely to avoid the possibility of unfiltered

air entering the engine.

CAUTION:

ECB00460

Make sure that the air filter element is prop- erly seated in the air filter case.

Never operate the engine with the air filter el- ement removed. This will allow unfiltered air to enter the engine, causing rapid engine wear and possible engine damage. Addition- ally, operation without the air filter element

1. Washer

1

8-19

1

2

3

4

5

6

7

8

9

10

11

will affect carburetor jetting with subsequent poor performance and possible engine over-

heating.

EBU28890

Cleaning the spark arrester

Be sure the exhaust pipe and muffler are cool be- fore cleaning the spark arrester. 1. Remove the bolts.

2. Remove the tailpipe by pulling it out of the muffler.

3. Tap the tailpipe lightly, and then use a wire brush to remove any carbon deposits from the spark arrester portion of the tailpipe and inside of the tailpipe housing.

4. Make sure the gasket is properly positioned, then insert the tailpipe into the muffler and align the bolt holes.

1. Bolt 2. Tailpipe

2

1

1

1. Tailpipe 2. Spark arrester

21

8-20

1

2

3

4

5

6

7

8

9

10

11

5. Install the bolts and tighten them to the speci- fied torque.

EWB01910

EBU23940

Adjusting the carburetor

The carburetor should be checked and, if neces- sary, adjusted at the intervals specified in the peri- odic maintenance and lubrication chart. The carburetor is an important part of the engine and requires very sophisticated adjustment. Therefore, most carburetor adjustments should be left to a Yamaha dealer, who has the necessary profes- sional knowledge and experience. The adjustment described in the following section, however, may be performed by the owner as part of routine main- tenance.

1. Gasket 2. Tailpipe 3. Bolt

Tightening torque: Tailpipe bolt:

11 Nm (1.1 mkgf, 8.0 ftlbf)

WARNING

POTENTIAL HAZARD Improper cleaning of the spark arrester. Hot exhaust system.

12

3

3

WHAT CAN HAPPEN Could injure the eyes. Could cause burns. Could cause carbon monoxide poisoning, possibly leading to death. Could start a fire. HOW TO AVOID THE HAZARD When cleaning the spark arrester: Always let the exhaust system cool prior to touching exhaust components. Do not start the engine when cleaning the ex- haust system.

8-21

1

2

3

4

5

6

7

8

9

10

11

CAUTION:

ECB00480

The carburetor has been set and extensively tested at the Yamaha factory. Changing these settings without sufficient technical knowl- edge may result in poor performance of or

damage to the engine.

EBU24000

Adjusting the engine idling speed

The engine idling speed must be checked and, if necessary, adjusted as follows at the intervals specified in the periodic maintenance and lubrica- tion chart.

NOTE:

A diagnostic tachometer is needed to make this

adjustment.

1. Start the engine and warm it up.

NOTE:

The engine is warm when it quickly responds to the

throttle.

2. Attach the tachometer to the spark plug lead. 3. Check the engine idling speed and, if neces-

sary, adjust it to specification by turning the

throttle stop screw at the carburetor. To in- crease the engine idling speed, turn the throt- tle stop screw in direction (a), and to decrease it, turn the screw in direction (b).

NOTE:

If the specified idling speed cannot be obtained as described above, have a Yamaha dealer make the

adjustment.

1. Throttle stop screw

Engine idling speed: 15001600 r/min

1

(a)(b)

8-22

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2

3

4

5

6

7

8

9

10

11

EBU24043

Adjusting the throttle cable free play

The throttle cable free play should be checked and, if necessary, adjusted at the intervals speci- fied in the periodic maintenance and lubrication chart. The throttle cable free play should measure 2.0 4.0 mm (0.080.16 in) at the throttle lever. Period- ically check the throttle cable free play and, if nec- essary, adjust it as follows.

NOTE:

The engine idling speed must be checked, and ad- justed if necessary, before adjusting the throttle ca-

ble free play.

1. Loosen the locknut. 2. To increase the throttle cable free play, turn

the adjusting bolt in direction (a). To decrease the throttle cable free play, turn the adjusting bolt in direction (b).

3. Tighten the locknut.

EBU24060

Valve clearance

The valve clearance changes with use, resulting in improper air-fuel mixture and/or engine noise. To prevent this from occurring, the valve clearance must be adjusted by a Yamaha dealer at the inter- vals specified in the periodic maintenance and lu- brication chart.

1. Locknut 2. Throttle cable free play adjusting bolt 3. Throttle lever free play

3

2 1

(a)

(b)

8-23

1

2

3

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5

6

7

8

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10

11

EBU24130

Checking the front and rear brake pads

The front and rear brake pads must be checked for wear at the intervals specified in the periodic main- tenance and lubrication chart.

EBU27711

Front brake pads

Each brake pad is provided with wear indicator grooves, which allow you to check the brake pad wear without having to disassemble the brake. To check the brake pad wear, check the wear indica- tor grooves. If a brake pad has worn to the point that the wear indicator grooves are almost in con- tact with the disc plate, have a Yamaha dealer re- place the brake pads as a set.

NOTE:

The wheels need to be removed to check the

brake pads. (See page 8-44.)

EBU24190

Rear brake pads

Each brake pad is provided with a wear indicator, which allows you to check the brake pad wear without having to disassemble the brake. To check the brake pad wear, check the position of the wear indicator while applying the brake. If a brake pad has worn to the point that the wear indicator almost touches the brake disc, have a Yamaha dealer re-

1. Wear indicator groove

1

8-24

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2

3

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10

11

place the brake pads as a set.

EBU28930

Checking the brake fluid level

Insufficient brake fluid may allow air to enter the brake system, possibly causing it to become inef- fective. Before riding, check that the brake fluid is above the minimum level mark and replenish if neces- sary. A low brake fluid level may indicate worn brake pads and/or brake system leakage. If the brake fluid level is low, be sure to check the brake pads for wear and the brake system for leakage.

Front brake

1. Wear indicator

1

1. Minimum level mark

1

8-25

1

2

3

4

5

6

7

8

9

10

11

Rear brake

If the rear brake fluid level is low, replenish as fol- lows. 1. Remove the brake fluid reservoir cap cover by

removing the bolt.

2. Remove the brake fluid reservoir cap.

1. Minimum level mark

1

1. Bolt 2. Brake uid reservoir cap cover

1

2

8-26

1

2

3

4

5

6

7

8

9

10

11

3. Refill with brake fluid. 4. Install the brake fluid reservoir cap. 5. Install the brake fluid reservoir cap cover by

installing the bolt. Observe these precautions:

When checking the fluid level, make sure that the top of the brake fluid reservoir is level.

Use only the recommended quality brake fluid, otherwise the rubber seals may deteriorate, causing leakage and poor braking performance.

Refill with the same type of brake fluid. Mixing fluids may result in a harmful chemical reaction and lead to poor braking performance.

Be careful that water does not enter the brake fluid reservoir when refilling. Water will signifi- cantly lower the boiling point of the fluid and may result in vapor lock.

Brake fluid may deteriorate painted surfaces or plastic parts. Always clean up spilled fluid imme- diately.

As the brake pads wear, it is normal for the brake fluid level to gradually go down. However, if the brake fluid level goes down suddenly, have a Yamaha dealer check the cause.

EBU24290

Changing the brake fluid

Have a Yamaha dealer change the brake fluid at the intervals specified in the NOTE after the peri- odic maintenance and lubrication chart. In addi- tion, have the oil seals of the master cylinders and calipers as well as the brake hoses replaced at the intervals listed below or whenever they are dam- aged or leaking.

Oil seals: Replace every two years.

Brake hoses: Replace every four years.

1. Brake uid reservoir cap

Recommended brake fluid: DOT 4

1

8-27

1

2

3

4

5

6

7

8

9

10

11

EBU24380

Checking the front brake lever free play

The brake lever free play must be checked at the intervals specified in the periodic maintenance and lubrication chart. The brake lever should have a free play of zero mm (zero in) as shown. If the free play is incorrect, have a Yamaha dealer check the brake system.

EWB02010

EBU24581

Checking the brake pedal position

The brake pedal position must be checked and, if necessary, adjusted at the intervals specified in the periodic maintenance and lubrication chart. The top of the brake pedal should be positioned 40.0 mm (1.57 in) above the top of the frame as shown. If the brake pedal is not positioned as spec- ified, have a Yamaha dealer adjust it.

1. Brake lever free play

WARNING

POTENTIAL HAZARD Operating with improperly serviced or ad- justed brakes.

1

WHAT CAN HAPPEN You could lose braking ability, which could lead to an accident. HOW TO AVOID THE HAZARD After servicing:

Make sure the brakes operate smoothly and that the free play is correct.

Make sure the brakes do not drag.

Make sure the brakes are not spongy. All air must be bled from the brake system.

Replacement of brake components requires professional knowledge. These procedures should be performed by a Yamaha dealer.

8-28

1

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3

4

5

6

7

8

9

10

11

EWB02060

EBU24700

Adjusting the parking brake free play

The parking brake free play must be checked and, if necessary, adjusted at the intervals specified in the periodic maintenance and lubrication chart. Cable length A should measure 6468 mm (2.522.60 in). Adjust the parking brake free play as follows.

1. Brake pedal position

WARNING

POTENTIAL HAZARD Operating with improperly serviced or ad- justed brakes. WHAT CAN HAPPEN You could lose braking ability, which could lead to an accident.

1

HOW TO AVOID THE HAZARD After servicing:

Make sure the brakes operate smoothly and that the brake pedal position is cor- rect.

Make sure the brakes do not drag.

Make sure the brakes are not spongy. All air must be bled from the brake system.

Replacement of brake components requires professional knowledge. These procedures should be performed by a Yamaha dealer.

8-29

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7

8

9

10

11

1. Release the parking brake by moving the parking brake lever to the right.

2. Fully loosen the locknut and the adjusting bolt at the rear brake caliper.

3. Loosen the locknut on the brake cable. 4. Turn the adjusting nut on the brake cable in di-

rection (a) to increase the cable length, and in direction (b) to decrease it.

NOTE:

If the cable length cannot be adjusted to specifica-

tion, consult a Yamaha dealer.

5. Tighten the locknut on the brake cable. 6. Turn in the adjusting bolt at the rear brake cal-

iper until it feels tight, then turn it out 1/8 turn and tighten its locknut to the specified torque.

CAUTION:

ECB00520

When tightening the locknut, hold the adjust- ing bolt with a wrench so that it does not turn

1. Adjusting bolt 2. Cable length A 3. Locknut

2

1

3

1. Locknut 2. Adjusting nut

2 1

(a)

(b)

8-30

1

2

3

4

5

6

7

8

9

10

11

together with the locknut.

EWB02030

EBU24740

Brake light switches

The operation of the brake light switches must be checked and, if necessary, adjusted at the inter-

vals specified in the periodic maintenance and lu- brication chart. The brake light switch for the brake pedal can be adjusted as follows, but the other brake light switches should be adjusted by a Yamaha dealer.

NOTE:

The brake light switch is properly adjusted when the brake light comes on just before braking takes

effect.

Turn the adjusting nut while holding the brake light switch in place. To make the brake light come on earlier, turn the adjusting nut in direction (a). To make the brake light come on later, turn the adjust- ing nut in direction (b).

Tightening torque: Locknut (rear brake caliper):

16 Nm (1.6 mkgf, 11.6 ftlbf)

WARNING

POTENTIAL HAZARD Operating with improperly serviced or ad- justed brakes. WHAT CAN HAPPEN The brakes could malfunction, causing re- duced braking performance. This could in- crease the chance of a collision or accident. HOW TO AVOID THE HAZARD After adjusting the parking brake free play, block the rear of the ATV off the ground and spin the rear wheels. Check to make sure there is no brake drag. If brake drag is no- ticed, perform the adjustment again.

8-31

1

2

3

4

5

6

7

8

9

10

11

EBU24810

Adjusting the clutch lever free play

The clutch lever free play must be checked and, if necessary, adjusted at the intervals specified in the periodic maintenance and lubrication chart. The clutch lever free play should measure 5.0 10.0 mm (0.200.39 in) as shown. If the free play is incorrect, adjust it as follows.

1. Loosen the locknut at the clutch lever. 2. To increase the clutch lever free play, turn the

adjusting bolt in direction (a), and to decrease it, turn the bolt in direction (b).

3. Tighten the locknut.

NOTE:

If the specified free play cannot be obtained as de- scribed above or if the clutch does not operate cor- rectly, have a Yamaha dealer check the internal

clutch mechanism.

1. Brake light switch 2. Brake light switch adjusting nut

1

2 (b)

(a)

1. Clutch lever free play 2. Clutch lever free play adjusting bolt 3. Locknut

1 2

(a)

(b)

3

8-32

1

2

3

4

5

6

7

8

9

10

11

EBU26861

Drive chain slack

The drive chain slack should be checked before each ride and adjusted if necessary.

To check the drive chain slack

1. Place the ATV on a level surface.

NOTE:

When checking and adjusting the drive chain slack, there should be no weight on the ATV and

all tires must be touching the ground.

2. Move the ATV back and forth to locate the tightest portion of the drive chain, and then measure the drive chain slack as shown.

3. If the drive chain slack is incorrect, adjust it as follows.

To adjust the drive chain slack

1. Loosen the rear axle pinch bolts. 2. Insert a rod of a diameter of 8 mm (0.3 in) and

a length of 10 cm (4 in) into one of the holes in the drive chain tensioner as shown.

Drive chain slack: 45.055.0 mm (1.772.17 in)

1. Drive chain slack

1

8-33

1

2

3

4

5

6

7

8

9

10

11

NOTE:

A rod can be obtained at a Yamaha dealer to make

this adjustment.

3. Shift the transmission into neutral. 4. To tighten the drive chain, push the ATV back-

ward. To loosen the drive chain, push the ATV forward.

CAUTION:

ECB00541

Improper drive chain slack will overload the en-

gine as well as other vital parts of the ATV and can lead to drive chain slippage or breakage. To prevent this from occurring, keep the drive

chain slack within the specified limits.

5. Pull the rod out, and then tighten the rear axle pinch bolts to the specified torque in the order shown.

EBU24880

Lubricating the drive chain

The drive chain must be cleaned and lubricated at the intervals specified in the periodic maintenance

1. Rear wheel axle pinch bolt 2. Rod 3. Drive chain tensioner 4. Hole

2 1 1

3

4

Tightening torque: Rear axle pinch bolt:

21 Nm (2.1 mkgf, 15.2 ftlbf)

1 2 3 4 5 6 7 8

8-34

1

2

3

4

5

6

7

8

9

10

11

and lubrication chart, otherwise it will quickly wear out, especially when riding in dusty or wet areas. Service the drive chain as follows.

CAUTION:

ECB00560

The drive chain must be lubricated after wash-

ing the ATV or riding in the rain.

1. Clean the drive chain with kerosene and a small soft brush.

CAUTION:

ECB00570

To prevent damaging the O-rings, do not clean

the drive chain with steam cleaners, high-pres-

sure washers or inappropriate solvents.

2. Wipe the drive chain dry. 3. Thoroughly lubricate the drive chain with a

special O-ring chain lubricant.

CAUTION:

ECB00580

Do not use engine oil or any other lubricants for the drive chain, as they may contain sub-

stances that could damage the O-rings.

EBU24890

Checking and lubricating the cables

The operation and the condition of all control ca- bles should be checked before each ride, and the cables and cable ends should be lubricated if nec- essary. If a cable is damaged or does not move smoothly, have a Yamaha dealer check or replace it.

1. O-rings

1

Recommended lubricant: Engine oil

8-35

1

2

3

4

5

6

7

8

9

10

11

EWB02120

EBU24921

Checking and lubricating the brake and clutch levers

The operation of the brake and clutch levers should be checked before each ride, and the lever pivots should be lubricated if necessary.

Brake lever

WARNING

POTENTIAL HAZARD Damaged control cables. WHAT CAN HAPPEN Corrosion can result when the cable sheaths become damaged, and cables can also be- come frayed or kinked, which could restrict the operation of controls and lead to an acci- dent or injury. HOW TO AVOID THE HAZARD Inspect cables frequently. Replace damaged cables.

Recommended lubricants: Brake lever:

Silicone grease Clutch lever:

Lithium-soap-based grease (all-purpose grease)

8-36

1

2

3

4

5

6

7

8

9

10

11

Clutch lever

EBU24931

Checking and lubricating the brake and shift pedals

The operation of the brake and shift pedals should be checked before each ride, and the pedal pivots should be lubricated if necessary.

EBU24962

Checking the wheel hub bearings

The front and rear wheel hub bearings must be checked at the intervals specified in the periodic maintenance and lubrication chart. If there is play in a wheel hub or if a wheel does not turn smoothly, have a Yamaha dealer check the wheel hub bear- ings.

EBU24992

Lubricating the swingarm pivots

The swingarm pivots must be lubricated at the in- tervals specified in the periodic maintenance and lubrication chart.

Recommended lubricants: Brake pedal:

Silicone grease Shift pedal:

Lithium-soap-based grease (all-purpose grease)

Recommended lubricant: Lithium-soap-based grease

8-37

1

2

3

4

5

6

7

8

9

10

11

EBU25030

Lubricating the upper and lower arm pivots

The upper and lower arm pivots must be lubricated at the intervals specified in the periodic mainte- nance and lubrication chart. Lubricate the pivoting points using a grease gun.

Left side

Recommended lubricant: Lithium-soap-based grease

1. Upper grease nipple 2. Lower grease nipple

2 1

8-38

1

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Right side

EBU25100

Lubricating the steering shaft

The steering shaft must be lubricated at the inter- vals specified in the periodic maintenance and lu- brication chart.

EBU25212

Battery

This model is equipped with a sealed-type (MF) battery, which does not require any maintenance. There is no need to check the electrolyte or to add distilled water. Check and, if necessary, tighten the battery lead connections.

CAUTION:

ECB00620

Never attempt to remove the battery cell seals,

as this would permanently damage the battery.

1. Upper grease nipple 2. Lower grease nipple

Recommended lubricant: Lithium-soap-based grease

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EWB02140

To charge the battery

Have a Yamaha dealer charge the battery as soon as possible if it seems to have discharged. Keep in mind that the battery tends to discharge more quickly if the ATV is equipped with optional electri- cal accessories.

To store the battery

1. If the ATV will not be used for more than one month, remove the battery, fully charge it, and then place it in a cool, dry place.

2. If the battery will be stored for more than two months, check it at least once a month and ful- ly charge it if necessary.

To install the battery

NOTE:

Be sure the battery is fully charged.

1. Place the battery in its compartment. 2. Make sure to properly connect the battery

leads to the battery terminals.

CAUTION:

ECB00630

Always keep the battery charged. Storing a discharged battery can cause permanent battery damage.

WARNING

POTENTIAL HAZARD Failure to handle batteries or battery electro- lyte carefully. WHAT CAN HAPPEN You could be poisoned. You could be severe- ly burned by the sulfuric acid in battery elec- trolyte. Batteries produce explosive gases. HOW TO AVOID THE HAZARD Avoid contact with skin, eyes or clothing. Al- ways shield eyes when working near batter- ies. Keep out of reach of children. Antidote: EXTERNAL: Flush with water. INTERNAL: Drink large quantities of water or milk. Follow with milk of magnesia, beaten egg or vegetable oil. Get prompt medical at- tention. EYES: Flush with water for 15 minutes and get prompt medical attention. Keep batteries away from sparks, flames, cigarettes or other sources of ignition. Ventilate when charging or using in a closed space.

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To charge a sealed-type (MF) battery, a spe- cial constant-voltage battery charger is re- quired. Using a conventional battery charger will damage the battery. If you do not have access to a constant-voltage battery charg- er, have a Yamaha dealer charge your bat-

tery.

EBU28911

Replacing the fuse

The fuse holder is located beside the battery and can be accessed as follows: 1. Remove the seat. (See page 4-12.) 2. Unhook the band, and then take out the own-

ers tool kit and the low-pressure tire gauge. 3. Remove the battery cover by removing the

battery cover bracket bolts.

1. Low-pressure tire gauge 2. Owners tool kit 3. Bolt 4. Battery cover

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If the fuse is blown, replace it as follows. 1. Turn the key to OFF and turn off all electrical

circuits.

CAUTION:

ECB00640

To prevent accidental short-circuiting, turn off the main switch when checking or replacing a

fuse.

2. Remove the blown fuse, and then install a new fuse of the specified amperage.

EWB02151

3. Turn the key to ON and turn on the electrical circuits to check if the devices operate.

4. If the fuse immediately blows again, have a Yamaha dealer check the electrical system.

5. Install the battery cover by installing the bat- tery cover bracket bolts.

6. Place the owners tool kit and the low-pres- sure tire gauge onto the battery cover, and then hook the band.

7. Install the seat.

1. Main fuse 2. Spare fuse

12

Specified fuse: 15.0 A

WARNING

POTENTIAL HAZARD Using an improper fuse. WHAT CAN HAPPEN An improper fuse can cause damage to the electrical system, which could lead to a fire. HOW TO AVOID THE HAZARD Always use a fuse of the specified rating. Never use a material in place of the proper fuse.

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EBU25430

Replacing a headlight bulb

If a headlight bulb burns out, replace it as follows. 1. Remove the headlight unit by removing the

bolts.

2. Disconnect the headlight coupler. 3. Remove the headlight bulb holder cover.

4. Remove the headlight bulb holder by pushing it in and turning it counterclockwise, and then remove the defective bulb.

1. Headlight assembly 2. Bolt

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2

1. Headlight bulb holder cover 2. Headlight coupler

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EWB02180

5. Place a new headlight bulb into position.

CAUTION:

ECB00650

Do not touch the glass part of the headlight bulb to keep it free from oil, otherwise the transparency of the glass, the luminosity of the bulb, and the bulb life will be adversely affect- ed. Thoroughly clean off any dirt and finger- prints on the headlight bulb using a cloth

moistened with alcohol or thinner.

6. Install the headlight bulb holder by pushing it in and turning it clockwise.

7. Install the headlight bulb holder cover.

1. Headlight bulb holder

WARNING

POTENTIAL HAZARD A headlight bulb is hot when it is on and im- mediately after it is turned off. WHAT CAN HAPPEN You can be burned, or a fire could start if the bulb touches something flammable. HOW TO AVOID THE HAZARD Wait for the bulb to cool before touching or removing it.

1

1. Do not touch the glass part of the bulb.

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8. Connect the headlight coupler. 9. Install the headlight unit by installing the bolts.

10. Adjust the headlight beam if necessary.

EBU25550

Adjusting a headlight beam

CAUTION:

ECB00690

It is advisable to have a Yamaha dealer make

this adjustment.

To raise a headlight beam, turn the adjusting screw in direction (a). To lower a headlight beam, turn the adjusting screw in direction (b).

EBU25580

Replacing the tail/brake light bulb

If the tail/brake light bulb burns out, have a Yamaha dealer replace it.

EBU25650

Removing a wheel

1. Loosen the wheel nuts.

Front

1. Headlight beam adjusting screw

1

(a)

(b)

1. Nut

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Rear

2. Elevate the ATV and place a suitable stand under the frame.

3. Remove the nuts from the wheel. 4. Remove the wheel.

EBU25670

Installing a wheel

1. Install the wheel and the nuts.

NOTE:

When installing a front wheel, make sure its arrow mark points toward the rotating direction of the

wheel.

Front

2. Lower the ATV to the ground. 3. Tighten the wheel nuts to the specified

torques.

EBU25710

Troubleshooting

Although Yamaha ATVs receive a thorough in-

1. Nut

1. Arrow mark

Tightening torques: Front wheel nut:

45 Nm (4.5 mkgf, 32.5 ftlbf) Rear wheel nut:

45 Nm (4.5 mkgf, 32.5 ftlbf)

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spection before shipment from the factory, trouble may occur during operation. Any problem in the fu- el, compression, or ignition systems, for example, can cause poor starting and loss of power. The following troubleshooting chart represents a quick and easy procedure for checking these vital systems yourself. However, should your ATV re- quire any repair, take it to a Yamaha dealer, whose skilled technicians have the necessary tools, expe- rience, and know-how to service the ATV properly. Use only genuine Yamaha replacement parts. Im- itation parts may look like Yamaha parts, but they are often inferior, have a shorter service life and can lead to expensive repair bills.

EWB02260

WARNING

POTENTIAL HAZARD Checking the fuel system while smoking or near an open flame. WHAT CAN HAPPEN Fuel can ignite or explode, causing severe in- jury or property damage.

HOW TO AVOID THE HAZARD Do not smoke when checking the fuel sys- tem. Make sure there are no open flames or sparks in the area, including pilot lights from water heaters or furnaces.

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EBU25751

Troubleshooting chart

Check the fuel level in the fuel tank.

1. Fuel There is enough fuel.

There is no fuel.

Check the compression.

Supply fuel. The engine does not start. Check the compression.

Operate the electric starter.

2. Compression There is compression.

There is no compression.

Check the ignition.

Have a Yamaha dealer check the ATV.

Remove the spark plug and check the electrodes.

3. Ignition Wipe off with a dry cloth and correct the spark plug gap, or replace the spark plug.

Have a Yamaha dealer check the ATV.

The engine does not start. Have a Yamaha dealer check the ATV.

The engine does not start. Check the battery.

Operate the electric starter.

4. Battery The engine turns over quickly.

The engine turns over slowly.

The battery is good.

Check the battery lead connections, and charge the battery if necessary.

Dry

Wet Open the throttle halfway and operate the electric starter.

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EBU25860

CLEANING AND STORAGE

EBU25890

Cleaning

Frequent, thorough cleaning of your ATV will not only enhance its appearance but will improve its general performance and extend the useful life of many components. 1. Before cleaning the ATV:

a. Block off the end of the exhaust pipe to prevent water entry. A plastic bag and strong rubber band may be used.

b. Make sure the spark plug and all filler caps are properly installed.

2. If the engine case is excessively greasy, apply degreaser with a paint brush. Do not apply de- greaser to the chain, sprockets or wheel ax- les.

3. Rinse the dirt and degreaser off with a garden hose. Use only enough pressure to do the job.

CAUTION:

ECB00710

Excessive water pressure may cause water seepage and deterioration of wheel bearings, brakes, transmission seals and electrical de- vices. Many expensive repair bills have result-

ed from improper high-pressure detergent applications such as those available in coin-

operated car washers.

4. Once most of the dirt has been hosed off, wash all surfaces with warm water and mild, detergent-type soap. An old toothbrush or bot- tle brush is handy for hard-to-reach places.

5. Rinse the ATV off immediately with clean wa- ter and dry all surfaces with a chamois, clean towel or soft absorbing cloth.

6. Dry the chain and lubricate it to prevent it from rusting.

7. Clean the seat with a vinyl upholstery cleaner to keep the cover pliable and glossy.

8. Automotive type wax may be applied to all painted and chrome plated surfaces. Avoid combination cleaner-waxes. Many contain abrasives which may mar the paint or protec- tive finish. When finished cleaning, start the engine and let it idle for several minutes.

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EWB02300

EBU25932

Storage

Short-term

Always store your ATV in a cool, dry place and, if necessary, protect it against dust with a porous cover.

CAUTION:

ECB00720

Storing the ATV in a poorly ventilated room or covering it with a tarp while it is still wet, will allow water and humidity to seep in and cause rust.

To prevent corrosion, avoid damp cellars, stables (because of the presence of ammo-

nia) and areas where strong chemicals are

stored.

Long-term

Before storing your ATV for several months: 1. Follow all the instructions in the Cleaning

section of this chapter. 2. Turn the fuel cock lever to OFF. 3. Drain the carburetor float chamber by loosen-

ing the drain bolt; this will prevent fuel deposits from building up. Pour the drained fuel into the fuel tank.

4. Fill up the fuel tank and add fuel stabilizer (if available) to prevent the fuel from deteriorat- ing.

5. Perform the following steps to protect the cyl- inder, piston rings, etc. from corrosion. a. Remove the spark plug cap and spark

plug. b. Pour a teaspoonful of engine oil into the

spark plug bore. c. Install the spark plug cap onto the spark

WARNING

POTENTIAL HAZARD Operation with wet brakes after washing. WHAT CAN HAPPEN Wet brakes may have reduced stopping abil- ity, increasing the chance of an accident. HOW TO AVOID THE HAZARD Test the brakes after washing. Apply the brakes several times at slow speeds to let friction dry out the linings.

Specified amount: 7.5 ml of stabilizer to each liter of fuel (or 1 oz of stabilizer to each gallon of fuel)

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plug, and then place the spark plug on the cylinder head so that the electrodes are grounded. (This will limit sparking during the next step.)

d. Turn the engine over several times with the starter. (This will coat the cylinder wall with oil.)

e. Remove the spark plug cap from the spark plug, and then install the spark plug and the spark plug cap.

6. Lubricate all control cables and the pivoting points of all levers and pedals.

7. Check and, if necessary, correct the tire air pressure, and then block up the ATV so that all of its wheels are off the ground. Alternative- ly, turn the wheels a little every month in order to prevent the tires from becoming degraded in one spot.

8. Cover the muffler outlet with a plastic bag to prevent moisture from entering it.

9. Remove the battery and fully charge it. Store it in a cool, dry place and charge it once a month. Do not store the battery in an exces- sively cold or warm place [less than 0 C (30 F) or more than 30 C (90 F)]. For more in- formation on storing the battery, see page

8-38.

NOTE:

Make any necessary repairs before storing the

ATV.

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EBU25960

SPECIFICATIONS

EBU2597A

Dimensions:

Overall length: 1625 mm (64.0 in)

Overall width: 1070 mm (42.1 in)

Overall height: 1040 mm (40.9 in)

Seat height: 730 mm (28.7 in)

Wheelbase: 1110 mm (43.7 in)

Ground clearance: 100 mm (3.9 in)

Minimum turning radius: 2900 mm (114 in)

Weight:

With oil and fuel: 150.0 kg (331 lb)

Engine:

Engine type: Air cooled 4-stroke, SOHC

Cylinder arrangement: Forward-inclined single cylinder

Displacement: 249.0 cm

3

Bore

stroke: 74.0

58.0 mm (2.91

2.28 in) Compression ratio:

9.50 :1 Starting system:

Electric starter Lubrication system:

Wet sump

Engine oil:

Type: YAMALUBE 4, SAE5W30 or SAE10W30 or SAE20W40

Recommended engine oil grade: API service SG type or higher, JASO standard MA

0 10 30 50 70 90 110 130F

YAMALUBE 4 (10W30) or SAE 10W30

YAMALUBE 4-CW (5W30) or SAE 5W30

-20 -10 0 10 20 30 40 50C

YAMALUBE 4 (20W40) or SAE 20W40

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Engine oil quantity: Without oil filter element replacement:

1.25 L (1.32 US qt) (1.10 Imp.qt) With oil filter element replacement:

1.35 L (1.43 US qt) (1.19 Imp.qt)

Air filter:

Air filter element: Wet element

Fuel:

Recommended fuel: Unleaded gasoline only

Fuel tank capacity: 9.0 L (2.38 US gal) (1.98 Imp.gal)

Fuel reserve amount: 1.0 L (0.26 US gal) (0.22 Imp.gal)

Carburetor:

Manufacturer: MIKUNI

Type x quantity: BSR29 x 1

Spark plug (s):

Manufacturer/model: NGK/DR7EA

Spark plug gap: 0.60.7 mm (0.0240.028 in)

Clutch:

Clutch type: Wet, multiple-disc

Operation: Left hand operation

Transmission:

Primary reduction system: Spur gear

Primary reduction ratio: 76/22 (3.455)

Secondary reduction system: Chain drive

Secondary reduction ratio: 38/14 (2.714)

Transmission type: Constant mesh 5-speed

Operation: Left foot operation

Gear ratio: 1st:

37/13 (2.846) 2nd:

33/18 (1.833) 3rd:

29/21 (1.381) 4th:

27/24 (1.125) 5th:

28/29 (0.966)

Chassis:

Frame type: Steel tube frame

Caster angle: 6.0

Trail: 23.0 mm (0.91 in)

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Front tire:

Type: Tubeless

Size: AT20 x 7-10

Manufacturer/model: DUNLOP/KT201

Rear tire:

Type: Tubeless

Size: AT19 x 10-9

Manufacturer/model: DUNLOP/KT205A

Loading:

Maximum loading limit: 100.0 kg (220 lb) (Total weight of rider, cargo, accessories, and tongue)

Tire air pressure (measured on cold tires):

Recommended: Front:

27.5 kPa (4.0 psi) (0.275 kgf/cm

2

) Rear:

27.5 kPa (4.0 psi) (0.275 kgf/cm

2

) Minimum:

Front: 24.5 kPa (3.5 psi) (0.245 kgf/cm

2

) Rear:

24.5 kPa (3.5 psi) (0.245 kgf/cm

2

)

Maximum: Front:

30.5 kPa (4.4 psi) (0.305 kgf/cm

2

) Rear:

30.5 kPa (4.4 psi) (0.305 kgf/cm

2

)

Front wheel:

Wheel type: Panel wheel

Rim size: 10 x 5.5AT

Rear wheel:

Wheel type: Panel wheel

Rim size: 9 x 8.5AT

Front brake:

Type: Dual disc brake

Operation: Right hand operation

Recommended fluid: DOT 4

Rear brake:

Type: Single disc brake

Operation: Right foot operation

Recommended fluid: DOT 4

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Front suspension:

Type: Double wishbone

Spring/shock absorber type: Coil spring/oil damper

Wheel travel: 190 mm (7.5 in)

Rear suspension:

Type: Swingarm

Spring/shock absorber type: Coil spring/gas-oil damper

Wheel travel: 200 mm (7.9 in)

Electrical system:

Ignition system: DC. CDI

Charging system: AC magneto

Battery:

Model: YTZ7S

Voltage, capacity: 12 V, 6.0 Ah

Headlight:

Bulb type: Krypton bulb

Bulb voltage, wattage x quantity:

Headlight: 12 V, 30.0/30.0 W

2

Tail/brake light: 12 V, 5.0/21.0 W

1 Neutral indicator light:

12 V, 1.7 W

1

Fuse:

Fuse: 15.0 A

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EBU25981

CONSUMER INFORMATION

EBU26011

Identification numbers

Record the key identification number, vehicle iden- tification number and model label information in the spaces provided below for assistance when or- dering spare parts from a Yamaha dealer or for ref- erence in case the ATV is stolen.

KEY IDENTIFICATION NUMBER:

VEHICLE IDENTIFICATION NUMBER:

MODEL LABEL INFORMATION:

EBU26020

Key identification number

The key identification number is stamped into the key. Record this number in the space provided and use it for reference when ordering a new key.

EBU26030

Vehicle identification number

The vehicle identification number is stamped into the frame.

1. Key identication number

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NOTE:

The vehicle identification number is used to identi-

fy your ATV.

EBU26050

Model label

The model label is affixed at the location in the il- lustration. Record the information on this label in the space provided. This information will be need- ed when ordering spare parts from a Yamaha deal- er.

1. Vehicle identication number

1

1. Model label

1

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EBU26060

Noise regulation

TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED:

Federal law prohibits the following acts or the causing thereof: (1) The removal or rendering inoperative by any person other than for purposes of maintenance, repair, or replacement of any device or element of de- sign incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use or (2) the use of the vehicle after such device or element of design has been removed or rendered inoperative by any person. AMONG THOSE ACTS PRESUMED TO CONSTITUTE TAMPERING ARE THE ACTS LISTED BELOW. These acts include tampering with the following systems; i.e., modification, removal, etc.

Exhaust system

Mufer

Exhaust pipe

Silencer

Intake system

Air cleaner case

Air cleaner element

Intake duct

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EBU26080

Maintenance record

Copies of work orders and/or receipts for parts you purchase and install will be required to document main- tenance done in accordance with the warranty. The chart below is printed only as a reminder to you that the maintenance work is required. It is not acceptable proof of maintenance work.

MAINTENANCE INTERVAL DATE OF SERVICE MILEAGE SERVICING DEALER

NAME AND ADDRESS REMARKS month km (mi) hours

1 320 (200) 20 3 1300 (800) 80 6 2500 (1600) 160

12 5000 (3200) 320 18 7500 (4800) 480 24 10000 (6400) 640 30 12500 (8000) 800 36 15000 (9600) 960 42 17500 (11200) 1120 48 20000 (12800) 1280 54 22500 (14400) 1440 60 25000 (16000) 1600

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EBU26501

YAMAHA MOTOR CORPORATION, U.S.A. ATV LIMITED WARRANTY

Yamaha Motor Corporation, U.S.A. hereby warrants that new Yamaha ATVs purchased from an authorized Yamaha ATV dealer in the continental United States will be free from defects in material and workmanship for the period of time stated herein, sub- ject to certain stated limitations.

THE PERIOD OF WARRANTY for Yamaha ATVs shall be six (6) months from the date of purchase.

DURING THE PERIOD OF WARRANTY any authorized Yamaha ATV dealer will, free of charge, repair or replace any part adjudged defective by Yamaha due to faulty workmanship or material from the factory. Parts used in warranty repairs will be warranted for the balance of the products warranty period. All parts replaced under warranty become property of Yamaha Motor Corp. U.S.A.

GENERAL EXCLUSIONS from this warranty shall include any failures caused by: a. Competition or racing use. b. Installation of parts or accessories that are not

qualitatively equivalent to genuine Yamaha parts. c. Abnormal strain, neglect, or abuse. d. Lack of proper maintenance. e. Accident or collision damage. f. Modification to original parts. g. Damage due to improper transportation.

SPECIFIC EXCLUSIONS from this warranty shall include parts replaced due to normal wear or routine maintenance, such as spark plugs, oil, oil filter, air filter, and brake shoes.

THE CUSTOMERS RESPONSIBILITY under this war- ranty shall be to: 1. Operate and maintain the ATV as specified in the

appropriate owners manual; 2. Give notice to an authorized Yamaha ATV dealer

of any and all apparent defects within ten (10) days after discovery, and make the machine available at that time for inspection and repairs at such dealers place of business.

WARRANTY TRANSFER: To transfer the warranty from the original purchaser to any subsequent pur- chaser(s), it is imperative that the machine be inspected and registered for warranty by an autho- rized Yamaha ATV dealer. In order for this warranty to remain in effect, this inspection and registration must take place within ten (10) days after transfer. An inspection and registration fee will be charged for this service.

EMISSION CONTROL SYSTEM WARRANTY Yamaha Motor Corporation, USA also warrants to the ultimate purchaser and each subsequent pur- chaser of each 2006 and later model Yamaha ATV covered by this warranty that the vehicle is designed, built, and equipped so as to conform at the time of sale with all U.S. emissions standards applicable at the time of manufacture and that it is free from defects in materials and workmanship which would cause it not to meet these standards

within the period listed immediately below. Failures other than those resulting from defects in material or workmanship which arise solely as a result of owner abuse and/or lack of proper maintenance are not covered by this warranty.

All Models Thirty (30) months from the original purchase date

YAMAHA MOTOR CORPORATION, U.S.A. MAKES NO OTHER WARRANTY OF ANY KIND, EXPRESSED OR IMPLIED. ALL IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE WHICH EXCEED THE OBLIGATIONS AND TIME LIMITS STATED IN THIS WARRANTY ARE HEREBY DISCLAIMED BY YAMAHA MOTOR CORPORATION, U.S.A. AND EXCLUDED FROM THIS WARRANTY.

SOME STATES DO NOT ALLOW LIMITATIONS ON HOW LONG AN IMPLIED WARRANTY LASTS, SO THE ABOVE LIMITATION MAY NOT APPLY TO YOU. ALSO EXCLUDED FROM THIS WARRANTY ARE ANY INCIDENTAL OR CONSEQUENTIAL DAMAGES INCLUDING LOSS OF USE. SOME STATES DO NOT ALLOW THE EXCLUSION OR LIMITATION OF INCIDENTAL OR CONSEQUENTIAL DAMAGES, SO THE ABOVE EXCLUSION MAY NOT APPLY TO YOU.

THIS WARRANTY GIVES YOU SPECIFIC LEGAL RIGHTS, AND YOU MAY ALSO HAVE OTHER RIGHTS WHICH VARY FROM STATE TO STATE.

YAMAHA MOTOR CORPORATION, U.S.A. P.O. Box 6555

Cypress, California 90630

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WARRANTY QUESTIONS AND ANSWERS

Q. What costs are my responsibility during the warranty period? A. The customers responsibility includes all costs of normal maintenance services,

non-warranty repairs, accident and collision damages, and oil, oil filters, air filters, spark plugs, and brake shoes.

Q. What are some examples of abnormal strain, neglect, or abuse? A. These terms are general and overlap each other in areas. Specific examples include:

Running the machine out of oil, sustained high rpm, full-throttle, operating the machine with a broken or damaged part which causes another part to fail, damage or failure due to improper or careless transportation and or tie-down. If you have any specific questions on operation or maintenance, please contact your dealer for advice.

Q. Does the warranty cover incidental costs such as towing or transportation due to a failure?

A. No. The warranty is limited to repair of the machine itself.

Q. May I perform any or all of the recommended maintenance shown in the Owners Manual instead of having the dealer do them?

A. Yes, if you are a qualified mechanic and follow the procedures specified in the Owners and Service Manual. We do recommend, however, that items requiring special tools or equipment be done by a Yamaha ATV dealer.

Q. Will the warranty be void or cancelled if I do not operate or maintain my new ATV exactly as specified in the Owners Manual?

A. No. The warranty on a new ATV cannot be voided or cancelled. However, if a particular failure is caused by operation or maintenance other than as described in the Owners Manual, that failure may not be covered under warranty.

Q. What responsibility does my dealer have under this warranty? A. Each Yamaha ATV dealer is expected to:

1. Completely set up every new machine before sale. 2. Explain the operation, maintenance, and warranty requirements to your satis-

faction at the time of sale, and upon your request at any later date. 3. Each Yamaha ATV dealer is held responsible for his setup, service and war-

ranty repair work.

Q. Is the warranty transferable to second owners? A. Yes. The remainder of the existing warranty can be transferred upon request. The

unit has to be inspected and re-registered by an authorized Yamaha ATV dealer for the policy to remain effective.

CUSTOMER SERVICE

If your machine requires warranty service, you must take it to any authorized Yamaha ATV dealer within the continental United States. Be sure to bring your warranty registration card or other valid proof of the original date of purchase. If a question or problem arises regarding warranty, first contact the owner of the dealership. Since all warranty matters are handled at the dealer level, this person is in the best position to help you. If you are still not satisfied and require additional assistance, please write:

YAMAHA MOTOR CORPORATION U.S.A. CUSTOMER RELATIONS DEPARTMENT

P.O. Box 6555 Cypress, California 90630

When contacting Yamaha Motor Corporation, U.S.A. dont forget to include any important information such as names, addresses, model, V.I.N. (frame number), dates, and receipts.

CHANGE OF ADDRESS

The federal government requires each manufacturer of a motor vehicle to maintain a complete, up-to-date list of all first purchasers against the possibility of a safety-related defect and recall. This list is compiled from the purchase registrations sent to Yamaha Motor Corporation, U.S.A. by the selling dealer at the time of your purchase.

If you should move after you have purchased your new ATV, please advise us of your new address by sending a postcard listing your ATV model name, V.I.N. (frame number), dealer number (or dealers name) as it is shown on your warranty card, your name and new mailing address. Mail to:

YAMAHA MOTOR CORPORATION, U.S.A. P.O. Box 6555

Cypress, California 90630 Attention: Warranty Department

This will ensure that Yamaha Motor Corporation, U.S.A. has an up-to-date registration record in accordance with federal law.

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EBU26122

YAMAHA EXTENDED SERVICE (Y.E.S.)

Keep your Yamaha protected even after your warranty expires with genuine Yamaha Extended Service (Y.E.S.).

Y.E.S. is designed and administered by Yamaha Motor Corporation to provide maximum owner satisfaction. You get uninterrupted factory-backed coverage for extra peace of mind.

Y. E. S. is flexible. You choose the plan thats right for you: 12 months, 24 months, or 36 months beyond your warranty period.

Y.E.S. is designed and administered by the same Yamaha people who handle your warranty and i t shows in the comprehensive coverage benefits. There are no mileage l imitat ions. Coverage isn t l imited to moving par ts or the drive train l ike many other plans. And Y.E.S. covers manufacturing defects just l ike the warranty. See the sample contract at your Yamaha dealer to see how comfor t ing uninterrupted factory- backed protection can be.

You don t have to pay anything for covered repairs. There s no deduc t ib le to pay, and repa i rs a ren t pro-rated. You don t have any out-of-pocket expenses for covered repairs.

In addition, Travel and Recreation Interruption Protection (TRIP) is included at no extra cost. TRIP gives you up to $150 reimbursement per occurrence for any reasonable expenses you incur because your Yamaha needs covered service: replacement vehicle rental, emergency towing, phone calls, even food and lodging when you are away from home. This superb coverage goes into effect when you purchase Y.E.S., so it applies to any warranty repairs as well as covered repairs during your entire Y.E.S. plan period.

Y.E.S. coverage is honored at any authorized Yamaha dealer nationwide.

Y.E.S. coverage is transferable to a new owner if you sell or trade in your ATV. That can make your Yamaha much more valuable!

This excellent Y.E.S. plan coverage is only available to Yamaha owners like you, and only while your Yamaha is still within the Yamaha Limited Warranty period. So visit your authorized Yamaha dealer to get all the facts. He can show you how easy it is to protect your investment with Yamaha Extended Service.

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We urge you to act now. Youll get the excellent benefits of TRIP coverage r ight away, and you l l rest easy knowing you l l have strong factory-backed protection even after your Yamaha Limited Warranty expires. You can also save money: Y.E.S. costs less within the first 90 days after you buy your Yamaha. See your dealer today!

A special note: If visiting your dealer isnt convenient, contact Yamaha with your Pr imary ID number (your frame number). We l l be happy to help you get the Y.E.S. coverage you need.

Yamaha Service Marketing P.O. Box 6555 Cypress, CA 90630

Indicates a potential hazard that could result in serious injury or death.

WARNING

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EBU26132

INDEX

A

Accessories and loading ................................................ 6-7 Air filter element, cleaning............................................ 8-15

B

Battery.......................................................................... 8-38 Brake and clutch levers, checking and lubricating ....... 8-35 Brake and shift pedals, checking and lubricating ......... 8-36 Brake fluid, changing.................................................... 8-26 Brake fluid level, checking............................................ 8-24 Brake lever ..................................................................... 4-5 Brake lever free play, checking the front...................... 8-27 Brake light switches ..................................................... 8-30 Brake pads, checking the front and rear ...................... 8-23 Brake pedal .................................................................... 4-6 Brake pedal position, checking .................................... 8-27 Brakes, front and rear .................................................... 5-4

C

Cables, checking and lubricating ................................. 8-34 Carburetor, adjusting.................................................... 8-20 Chassis fasteners........................................................... 5-9 Cleaning ......................................................................... 9-1 Clutch lever .................................................................... 4-5 Clutch lever free play, adjusting ................................... 8-31

D

Drive chain ..................................................................... 5-5 Drive chain, lubricating................................................. 8-33

Drive chain slack .......................................................... 8-32

E

Engine break-in .............................................................. 6-5 Engine, cold start ........................................................... 6-1 Engine idling speed...................................................... 8-21 Engine oil ....................................................................... 5-4 Engine oil and oil filter element .................................... 8-11 Engine, starting a warm ................................................. 6-3 Engine stop switch ......................................................... 4-2

F

Fuel ........................................................................ 4-8

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5-4 Fuel cock...................................................................... 4-10 Fuel tank cap.................................................................. 4-8 Fuse, replacing............................................................. 8-40

H

Handlebar switches........................................................ 4-2 Headlight beam, adjusting............................................ 8-44 Headlight bulb, replacing.............................................. 8-42

I

Identification numbers .................................................. 11-1 Indicator light.................................................................. 4-2 Instruments, lights and switches .................................... 5-9

K

Key identification number............................................. 11-1

L

Label locations ............................................................... 2-1

Light switch .................................................................... 4-3

M

Main switch .................................................................... 4-1 Maintenance and lubrication chart ................................. 8-5 Maintenance chart, emission control system ................. 8-3 Maintenance record ..................................................... 11-4 Model label................................................................... 11-2

N

Neutral indicator light ..................................................... 4-2 Noise regulation ........................................................... 11-3

O

Owners manual and tool kit ........................................... 8-1

P

Parking ........................................................................... 6-6 Parking brake free play, adjusting................................ 8-28 Parking brake lever ........................................................ 4-6 Parking on a slope ......................................................... 6-6 Part locations ................................................................. 3-1 Pre-operation check list.................................................. 5-1

R

Riding your ATV ............................................................. 7-1

S

Safety information .......................................................... 1-1 Seat.............................................................................. 4-12 Shifting ........................................................................... 6-3 Shift pedal ...................................................................... 4-7 Shock absorber assemblies, adjusting the front .......... 4-13 Spark arrester, cleaning ............................................... 8-19 Spark plug, checking...................................................... 8-9 Specifications ............................................................... 10-1 Speed limiter .................................................................. 4-4

Starter (choke) ............................................................. 4-11 Start switch..................................................................... 4-3 Steering shaft, lubricating............................................. 8-38 Storage........................................................................... 9-2 Suspension, lubricating the upper and lower arm

pivots.......................................................................... 8-37 Swingarm pivots, lubricating ........................................ 8-36

T

Tail/brake light bulb, replacing ..................................... 8-44 Throttle cable free play, adjusting ................................ 8-22 Throttle lever .......................................................... 4-3

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5-5 Tire pressure, measuring ............................................... 5-8 Tires ............................................................................... 5-7 Tire wear limit ................................................................. 5-9 Troubleshooting ........................................................... 8-45 Troubleshooting chart .................................................. 8-47

V

Valve clearance............................................................ 8-22 Vehicle identification number ....................................... 11-1

W

Warranty, extended...................................................... 11-7 Warranty, limited .......................................................... 11-5 Wheel hub bearings, checking ..................................... 8-36 Wheel, installing ........................................................... 8-45 Wheel, removing .......................................................... 8-44

PRINTED IN JAPAN 2007.05-1.8x1 !

(E)

YAMAHA MOTOR CO., LTD. PRINTED ON RECYCLED PAPER

LOCATE AND READ OWNERS MANUAL. FOLLOW ALL INSTRUCTIONS AND WARNINGS. (For replacement manual, call 1-800-532-1558)

WARNING

ALWAYS: use proper riding techniques to avoid vehicle overturns on hills and rough terrain and in turns. avoid paved surfaces-pavement may seriously affect handling and control.

Improper ATV use can result in SEVERE INJURY or DEATH.

NEVER operate: without proper training or instruction. at speeds too fast for your skills or the conditions. on public roads-a collision can occur with another vehicle. with a passenger-passengers affect balance and steering and increase risk of losing control.

ALWAYS USE AN APPROVED HELMET AND

PROTECTIVE GEAR

NEVER USE ON PUBLIC

ROADS

NEVER CARRY PASSENGERS

NEVER USE WITH DRUGS OR ALCOHOL

B EE R

B EE R

EBU26141

Dear New Yamaha ATV Owner:

CONGRATULATIONS ON THE PURCHASE OF YOUR NEW YAMAHA ATV. You have purchased a quality Yamaha product that, with proper use and care, will provide hours of riding pleasure. BEFORE YOU OPERATE YOUR NEW ATV, Yamaha recommends these important points:

8 READ YOUR OWNERS MANUAL

8 A CHILD UNDER 6 YEARS OLD SHOULD NOT OPERATE AN ATV WITH ENGINE SIZE 50CC OR GREATER

8 A CHILD UNDER 12 YEARS OLD SHOULD NOT OPERATE AN ATV WITH ENGINE SIZE 70CC OR GREATER

8 A CHILD UNDER 16 YEARS OLD SHOULD NOT OPERATE AN ATV WITH ENGINE SIZE GREATER THAN 90CC

8 TAKE THE FREE HANDS-ON TRAINING COURSE OFFERED BY YAMAHA ASK YOUR DEALER FOR DETAILS OR CALL 1-800-887-2887

If you have any questions about these points, or if you purchased your ATV from an authorized Yamaha dealership and were not informed of the age recommendation for your ATV by the dealership, please fill out the information below and mail this card to yamaha today.

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Name:

Address:

Telephone:

Dealer Name & Address:

Primary I.D. [Engine Number]:

ATV Model: Purchase Date:

MO. DAY YR.

[ ]

ATV card for US 4/2/03 9:06 AM Page 1

NO POSTAGE NECESSARY IF MAILED

IN THE UNITED STATES

Manualsnet FAQs

If you want to find out how the YFM25RX Yamaha works, you can view and download the Yamaha YFM25RX Raptor 250 2008 Owner's Manual on the Manualsnet website.

Yes, we have the Owner's Manual for Yamaha YFM25RX as well as other Yamaha manuals. All you need to do is to use our search bar and find the user manual that you are looking for.

The Owner's Manual should include all the details that are needed to use a Yamaha YFM25RX. Full manuals and user guide PDFs can be downloaded from Manualsnet.com.

The best way to navigate the Yamaha YFM25RX Raptor 250 2008 Owner's Manual is by checking the Table of Contents at the top of the page where available. This allows you to navigate a manual by jumping to the section you are looking for.

This Yamaha YFM25RX Raptor 250 2008 Owner's Manual consists of sections like Table of Contents, to name a few. For easier navigation, use the Table of Contents in the upper left corner.

You can download Yamaha YFM25RX Raptor 250 2008 Owner's Manual free of charge simply by clicking the “download” button in the upper right corner of any manuals page. This feature allows you to download any manual in a couple of seconds and is generally in PDF format. You can also save a manual for later by adding it to your saved documents in the user profile.

To be able to print Yamaha YFM25RX Raptor 250 2008 Owner's Manual, simply download the document to your computer. Once downloaded, open the PDF file and print the Yamaha YFM25RX Raptor 250 2008 Owner's Manual as you would any other document. This can usually be achieved by clicking on “File” and then “Print” from the menu bar.